Shotcrete Quality Control and Testing for an Underground ... - saimm
Shotcrete Quality Control and Testing for an Underground ... - saimm
Shotcrete Quality Control and Testing for an Underground ... - saimm
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<strong>Shotcrete</strong> <strong>Quality</strong> <strong>Control</strong> <strong><strong>an</strong>d</strong> <strong>Testing</strong> <strong>for</strong><br />
<strong>an</strong> <strong>Underground</strong> Mine in C<strong>an</strong>ada<br />
By<br />
Dudley R. (Rusty) Morg<strong>an</strong><br />
<strong><strong>an</strong>d</strong><br />
Mazin Ezzet<br />
AMEC Earth & Environmental,<br />
a division of AMEC Americas Limited<br />
SHOTCRETE FOR AFRICA CONFERENCE<br />
Misty Hills Conference Centre<br />
South Africa<br />
2-3 March, 2009
Subject of Presentation<br />
General Introduction<br />
St<strong><strong>an</strong>d</strong>ards <strong><strong>an</strong>d</strong> Codes<br />
<strong>Shotcrete</strong> Materials Requirements<br />
– Cementing Materials<br />
– Aggregates<br />
– Mixing Water<br />
– Chemical Admixtures<br />
<strong>Shotcrete</strong> Per<strong>for</strong>m<strong>an</strong>ce Requirements
Subject of Presentation (continued)<br />
<strong>Quality</strong> <strong>Control</strong> <strong>Testing</strong><br />
– Aggregates<br />
– Batching <strong><strong>an</strong>d</strong> Supply (Plastic <strong>Shotcrete</strong>)<br />
– Hardened <strong>Shotcrete</strong>
<strong>Shotcrete</strong> <strong>Quality</strong> <strong>Control</strong> Org<strong>an</strong>izational Chart
New <strong>Underground</strong> Gold Mine in British Columbia
Portal at Decline into <strong>Underground</strong> Mine
Mobile Mass Batcher Unit<br />
Discharging into Ready-Mix Concrete Truck
Remixer Unit <strong>for</strong> Hauling <strong>Shotcrete</strong> Down Decline
Remixer Unit Discharging into<br />
<strong>Shotcrete</strong> Pump at Back of <strong>Shotcrete</strong> Sprayer
Remote <strong>Control</strong> <strong>Shotcrete</strong> Sprayer
M<strong>an</strong>ipulator Arm on<br />
Remote <strong>Control</strong> <strong>Shotcrete</strong> Sprayer<br />
Shooting ASTM C1550 Round Test P<strong>an</strong>els
Ready <strong>for</strong> Shotcreting <strong>Underground</strong>
Drilling Face <strong>for</strong> next Round of Blasting<br />
Note <strong>Shotcrete</strong> with Bolts <strong><strong>an</strong>d</strong> Plates
St<strong><strong>an</strong>d</strong>ards <strong><strong>an</strong>d</strong> Codes<br />
Americ<strong>an</strong> Concrete Institute (ACI)<br />
Americ<strong>an</strong> Society <strong>for</strong> <strong>Testing</strong> <strong><strong>an</strong>d</strong> Materials (ASTM)<br />
C<strong>an</strong>adi<strong>an</strong> St<strong><strong>an</strong>d</strong>ards Association (CSA)<br />
National Ready Mix Concrete Association (NRMCA)<br />
Concrete Pl<strong>an</strong>t M<strong>an</strong>ufacturer’s Bureau (CPMP)
St<strong><strong>an</strong>d</strong>ards <strong><strong>an</strong>d</strong> Codes<br />
ASTM C114<br />
ASTM C642-82<br />
ASTM C1116<br />
ASTM C1140<br />
ASTM C1141<br />
ASTM C1436<br />
ASTM C1550<br />
ASTM C1602<br />
ASTM C1604<br />
St<strong><strong>an</strong>d</strong>ard Test Methods <strong>for</strong> Chemical Analysis of Hydraulic<br />
Cements<br />
St<strong><strong>an</strong>d</strong>ard Test Method <strong>for</strong> Specific Gravity, Absorption, <strong><strong>an</strong>d</strong> Voids<br />
in Hardened Concrete<br />
Specification <strong>for</strong> Fibre Rein<strong>for</strong>ced Concrete<br />
St<strong><strong>an</strong>d</strong>ard Practice <strong>for</strong> Preparing <strong><strong>an</strong>d</strong> <strong>Testing</strong> Specimens from<br />
<strong>Shotcrete</strong> Test P<strong>an</strong>els<br />
Specification <strong>for</strong> Admixtures <strong>for</strong> <strong>Shotcrete</strong><br />
St<strong><strong>an</strong>d</strong>ard Specification <strong>for</strong> Materials <strong>for</strong> <strong>Shotcrete</strong><br />
St<strong><strong>an</strong>d</strong>ard Specification <strong>for</strong> Flexural Toughness of Fibre Rein<strong>for</strong>ced<br />
Concrete (Using Centrally Loaded Round P<strong>an</strong>el)<br />
St<strong><strong>an</strong>d</strong>ard Specification <strong>for</strong> Mixing Water Used in Production of<br />
Hydraulic Cement Concrete<br />
St<strong><strong>an</strong>d</strong>ard Test Method <strong>for</strong> Obtaining <strong><strong>an</strong>d</strong> <strong>Testing</strong> Drilled Cores of<br />
<strong>Shotcrete</strong>
St<strong><strong>an</strong>d</strong>ards <strong><strong>an</strong>d</strong> Codes (continued)<br />
Americ<strong>an</strong> Concrete Institute (ACI)<br />
ACI 506R-05<br />
ACI 506.2-95<br />
C<strong>an</strong>adi<strong>an</strong> St<strong><strong>an</strong>d</strong>ards Association (CSA)<br />
CSA A23.1-04<br />
CSA A23.2-04<br />
CSA A3001-03<br />
Guide to <strong>Shotcrete</strong><br />
Specifications <strong>for</strong> Materials Proportioning <strong><strong>an</strong>d</strong> Application of<br />
<strong>Shotcrete</strong><br />
Concrete Materials <strong><strong>an</strong>d</strong> Methods of Concrete Construction<br />
Methods of Test <strong><strong>an</strong>d</strong> St<strong><strong>an</strong>d</strong>ard Practices <strong>for</strong> Concrete<br />
Cementitious Materials <strong>for</strong> Use in Concrete
<strong>Shotcrete</strong> Materials<br />
Cementing Materials<br />
– Portl<strong><strong>an</strong>d</strong> Cement: CSA Type GU<br />
– Fly Ash: CSA Type F or CI<br />
– Silica Fume: CSA Type SF<br />
Other Cementing Materials<br />
– Natural Pozzol<strong>an</strong>s<br />
– Calcined Metakaolins<br />
– Ground Gr<strong>an</strong>ulated Blast Furnace Slag
Limits <strong>for</strong> Deleterious Subst<strong>an</strong>ces <strong><strong>an</strong>d</strong><br />
Physical Properties of Aggregates<br />
CSA Test<br />
Method<br />
A23.2-3A<br />
A23.2-4A<br />
A23.2-5A<br />
A23.2-13A<br />
A23.2-23A<br />
A23.2-29A<br />
A23.2-16A<br />
A23.2-9A<br />
Property<br />
St<strong><strong>an</strong>d</strong>ard Requirements<br />
Clay lumps<br />
Low-density gr<strong>an</strong>ular materials<br />
Material finer th<strong>an</strong> 80 µm<br />
Flat <strong><strong>an</strong>d</strong> elongated particles<br />
Procedure A, ratios 4:1<br />
Micro-Deval test<br />
Unconfined freeze-thaw test<br />
Impact <strong><strong>an</strong>d</strong> abrasion loss<br />
MgSO 4 soundness loss<br />
Maximum Percentage by<br />
Mass of Total Sample<br />
Fine Aggregate<br />
1<br />
0.5<br />
3.0<br />
-<br />
20<br />
-<br />
-<br />
16<br />
Coarse<br />
Aggregate<br />
0.25<br />
0.5<br />
1.0<br />
20<br />
17<br />
6<br />
50<br />
12
Grading Limits <strong>for</strong> Fine Aggregate<br />
Total Passing Sieve, Percentage by Mass<br />
Sieve Size<br />
10 mm<br />
5 mm<br />
2.5 mm<br />
1.25 mm<br />
630 µm<br />
315 µm<br />
160 µm<br />
80 µm<br />
FA1<br />
100<br />
95-100<br />
80-100<br />
50-90<br />
25-65<br />
10-35<br />
2-10<br />
0-3
Grading Limits <strong>for</strong> Coarse Aggregate<br />
Nominal Size of Aggregate<br />
14 mm<br />
10 mm<br />
5 mm<br />
2.5 mm<br />
1.25 mm<br />
Total Passing Sieve, Percentage by Mass<br />
100<br />
85-100<br />
10-30<br />
0-10<br />
0-5
Grading Limits <strong>for</strong> Combined Aggregates<br />
Sieve Size<br />
14 mm<br />
10 mm<br />
5 mm<br />
2.5 mm<br />
1.25<br />
630 µm<br />
315 µm<br />
160 µm<br />
80 µm<br />
Total passing sieve, percentage by mass<br />
100<br />
90-100<br />
70-85<br />
50-70<br />
35-55<br />
20-35<br />
8-20<br />
2-10<br />
0-3
Percent Passing<br />
Graph of ACI No. 1 & No. 2 Gradings<br />
120<br />
100<br />
80<br />
60<br />
40<br />
20<br />
ACI Gradation 1 Limits<br />
ACI Gradation 2 Limits<br />
Combined % Passing<br />
0<br />
0.08 0.16 0.315 0.63 1.25 2.5 5 10 14<br />
Metric Sieve Size
Chemical Limits <strong>for</strong> Mixing Water<br />
Maximum Concentration<br />
In Mixing Water, ppm<br />
Chloride as Cl<br />
Sulphate as SO<br />
Alkalies as (Na 2 O + 0.658 K 2 O)<br />
Total solids by mass<br />
Limits<br />
1000<br />
3000<br />
600<br />
50,000<br />
ASTM Test Method<br />
C114<br />
C114<br />
C114<br />
C1603
Chemical Admixtures<br />
Water Reducing Admixtures<br />
Set Retarding or Hydration <strong>Control</strong>ling Admixtures<br />
Air Entraining Admixtures<br />
Set Accelerators Added at Nozzle
Fibres<br />
Steel Fibres:<br />
ASTM C1116 Type I <strong><strong>an</strong>d</strong> ASTM A 820<br />
Synthetic Fibres:<br />
ASTM C1116 Type III
Typical <strong>Shotcrete</strong> Per<strong>for</strong>m<strong>an</strong>ce Requirements<br />
Test Method<br />
-<br />
CSA A23.2 – 5C<br />
-<br />
CSA A23.2 – 4C<br />
Penetrometer as calibrated<br />
against beams tested as<br />
equivalent cubes<br />
ASTM C1604 & CSA A23.2 –<br />
14C<br />
ASTM C642<br />
ASTM C1550<br />
Air content – as shot<br />
Property<br />
Maximum water/cementing materials ratio<br />
Slump<br />
(at discharge into shotcrete pump)<br />
Temperature<br />
(at discharge into shotcrete pump)<br />
Minimum early age compressive strength<br />
be<strong>for</strong>e re-entry under shotcrete<br />
Minimum compressive strength of<br />
shotcrete cores<br />
1 Day<br />
7 Days<br />
28 Days<br />
Maximum values of boiled absorption<br />
Maximum volume of permeable voids<br />
Minimum Joules energy at 40 mm<br />
deflection in round p<strong>an</strong>el test<br />
Per<strong>for</strong>m<strong>an</strong>ce Requirement<br />
0.40<br />
170 ±20 mm<br />
10-30 o C<br />
2-5 %<br />
2 MPa<br />
10MPa<br />
30 MPa<br />
40 MPa<br />
9 %<br />
18 %<br />
*
Fibre Rein<strong>for</strong>ced <strong>Shotcrete</strong> <strong>Testing</strong> in North America<br />
Steel fibre synthetic macro-fibre rein<strong>for</strong>ced shotcrete in North<br />
America has been tested to the following ASTM St<strong><strong>an</strong>d</strong>ards:<br />
ASTM C1018: St<strong><strong>an</strong>d</strong>ard test method <strong>for</strong> flexural toughness <strong><strong>an</strong>d</strong><br />
first-crack strength of fiber-rein<strong>for</strong>ced concrete (using beam with<br />
third point loading) first published 1984, withdrawn 2006<br />
ASTM C1609: St<strong><strong>an</strong>d</strong>ard test method <strong>for</strong> flexural per<strong>for</strong>m<strong>an</strong>ce of<br />
fiber-rein<strong>for</strong>ced concrete (using beam with third point loading)<br />
first published 2005<br />
ASTM C1550: St<strong><strong>an</strong>d</strong>ard test method <strong>for</strong> flexural toughness of<br />
fiber rein<strong>for</strong>ced concrete (using centrally loaded round p<strong>an</strong>el)
ASTM C1018 <strong><strong>an</strong>d</strong> ASTM C1609 Beam Test
Fibre <strong>Shotcrete</strong> Tests<br />
ASTM C1018 Load vs Deflection Curve<br />
Test Results Include:<br />
– First crack <strong><strong>an</strong>d</strong> ultimate flexural strengths (MPa)<br />
– Toughness Indices I5 , I10 , I20 , etc<br />
– Residual Strength Factors R 5 , 10 , R 10 , 20 , etc.<br />
Problems of reliability with this test method <strong><strong>an</strong>d</strong> withdrawn in 2006
Flexural Toughness Per<strong>for</strong>m<strong>an</strong>ce Levels<br />
Morg<strong>an</strong> <strong><strong>an</strong>d</strong> Chen, 1995
Fibre <strong>Shotcrete</strong> Beam Tests<br />
ASTM C1609 Load vs Deflection Curve
ASTM C1550 Round P<strong>an</strong>el Test
ASTM C1550 Round P<strong>an</strong>el Test
Technical Report
Typical <strong>Shotcrete</strong> Mixture Design<br />
Cement Type GU<br />
Silica Fume<br />
Estimated Water, L<br />
Air Content:<br />
At Pump (+/- 1.5%)<br />
Total<br />
Material<br />
Coarse Aggregate (10-2.5mm, SSD)<br />
Fine Aggregate (SSD)<br />
High Water Reducing Admixture, L<br />
Hydration <strong>Control</strong>ling Admixture, L<br />
Macro Synthetic Fibre<br />
At Shot (%)<br />
Mass per m 3 SSD<br />
Agg [kg]<br />
430<br />
45<br />
380<br />
1310<br />
185<br />
2.5<br />
1.2<br />
6.0<br />
2.5<br />
2.0<br />
2354<br />
Density<br />
[kg/m3 ]<br />
3150<br />
2200<br />
2744<br />
2649<br />
1000<br />
1000<br />
1000<br />
910<br />
-<br />
-<br />
Yield (m3) =<br />
Volume<br />
[m3 ]<br />
0.1365<br />
0.0205<br />
0.1385<br />
0.4945<br />
0.1850<br />
0.0025<br />
0.0012<br />
0.0066<br />
-<br />
0.0202<br />
1.0105
<strong>Shotcrete</strong> <strong>Quality</strong> <strong>Control</strong> Certification <strong><strong>an</strong>d</strong> <strong>Testing</strong><br />
Aggregates<br />
Batch Pl<strong>an</strong>t<br />
Mixers<br />
Plastic <strong>Shotcrete</strong><br />
Hardened <strong>Shotcrete</strong>
<strong>Shotcrete</strong> Aggregates <strong>Testing</strong> Frequency<br />
CSA Test Method<br />
A23.2-3A<br />
A23.2-4A<br />
A23.2-5A<br />
A23.2-13A<br />
A23.2-23A<br />
A23.2-24A<br />
A23.2-16A<br />
A23.2-9A<br />
A23.2-15<br />
A23.2-25A<br />
A23.2-2A<br />
A23.2-6A<br />
A23.2-7A<br />
A23.2-12A<br />
A23.2-11A<br />
Clay Lumps<br />
Material Finer th<strong>an</strong> 80 µm<br />
Micro-Deval Test<br />
Impact <strong><strong>an</strong>d</strong> Abrasion Loss<br />
MgSO 4 Soundness Loss<br />
Petrographic Analysis<br />
Alkali Silica Reactivity<br />
Property<br />
Low Density Gr<strong>an</strong>ular Materials<br />
Flat <strong><strong>an</strong>d</strong> Elongated Particles<br />
Unconfined Freeze-thaw Test<br />
Sieve Analysis of Fine <strong><strong>an</strong>d</strong> Coarse Aggregates<br />
Relative Density <strong><strong>an</strong>d</strong> Absorption of Fine Aggregates<br />
Org<strong>an</strong>ic Impurities Colour Test<br />
Relative Density <strong><strong>an</strong>d</strong> Absorption of Coarse Aggregate<br />
Surface Moisture in Fine <strong><strong>an</strong>d</strong> Coarse Aggregates<br />
<strong>Testing</strong> Frequency<br />
6 months<br />
6 months<br />
1 week<br />
6 months<br />
6 months<br />
6 months<br />
6 months<br />
6 months<br />
1 year<br />
1 year<br />
Each delivery<br />
6 months<br />
1 week<br />
6 months<br />
Each day
<strong>Shotcrete</strong> Batching <strong><strong>an</strong>d</strong> Supply Certification <strong><strong>an</strong>d</strong> <strong>Testing</strong><br />
Test Method<br />
NRMCA CPMB 100 M-07<br />
NRMCA CPMB 100 M-07<br />
NRMCA CPMB 100 M-07<br />
Test Procedure<br />
Certification of ready mixed concrete<br />
production facilities using truck mixing<br />
Certification of ready mix concrete<br />
truck mixers <strong><strong>an</strong>d</strong> remixer units<br />
Batch records with solid materials in<br />
kg <strong><strong>an</strong>d</strong> liquids in L<br />
<strong>Testing</strong> Frequency<br />
At start of project <strong><strong>an</strong>d</strong> every 2<br />
years<br />
Be<strong>for</strong>e use <strong><strong>an</strong>d</strong> every 6<br />
months<br />
Each batch of shotcrete<br />
produced
Plastic <strong>Shotcrete</strong> QC <strong>Testing</strong><br />
Test Method<br />
CSA A23.2-5C<br />
CSA A23.2-5C<br />
CSA A23.2-7C<br />
CSA A23.2-7C<br />
Modified<br />
CSA A23.2-7C<br />
Modified<br />
Test Procedure<br />
Slump at discharge into remixer unit<br />
Slump at discharge into shotcrete<br />
pump<br />
<strong>Shotcrete</strong> <strong><strong>an</strong>d</strong> ambient temperatures<br />
at discharge into remixer unit <strong><strong>an</strong>d</strong> at<br />
shotcrete pump<br />
Air content of plastic shotcrete at<br />
discharge into remixer unit <strong><strong>an</strong>d</strong> at<br />
shotcrete pump<br />
Air Content as-shot (without<br />
accelerator)<br />
Wash-out test to determine uni<strong>for</strong>mity<br />
of fibre distribution at discharge from<br />
remixer unit<br />
<strong>Testing</strong> Frequency<br />
Each batch of shotcrete<br />
produced<br />
At beginning of each shift<br />
Each batch of shotcrete<br />
produced<br />
At start of project <strong><strong>an</strong>d</strong> with <strong>an</strong>y<br />
ch<strong>an</strong>ge in mixture proportions<br />
At start of project <strong><strong>an</strong>d</strong> with <strong>an</strong>y<br />
ch<strong>an</strong>ge of mixture proportions<br />
At start of project <strong><strong>an</strong>d</strong> with <strong>an</strong>y<br />
ch<strong>an</strong>ge in fibre type or dosage
Hardened <strong>Shotcrete</strong> QC <strong>Testing</strong><br />
Test Method<br />
Ref. 1<br />
Penetrometer<br />
ASTM C1140<br />
ASTM C1604<br />
ASTM C642<br />
ASTM C1550<br />
ASTM C1550<br />
Test Description<br />
Early age compressive strength of beams as<br />
equivalent cubes<br />
Early age compressive strength estimate<br />
using penetrometer<br />
Compressive strength of cores extracted<br />
from shotcrete test p<strong>an</strong>el at age 1 day (1<br />
core), 7 days (1 core) <strong><strong>an</strong>d</strong> 28 days (2 cores)<br />
Boiled absorption <strong><strong>an</strong>d</strong> volume of permeable<br />
voids<br />
Round p<strong>an</strong>el test to 40mm deflection<br />
Round p<strong>an</strong>el test to 40 mm deflection<br />
<strong>Testing</strong> Frequency<br />
At start of project <strong><strong>an</strong>d</strong> with <strong>an</strong>y<br />
ch<strong>an</strong>ge in mixture proportions or<br />
accelerator type or dosage<br />
One heading per shift<br />
One heading per week <strong>for</strong> each<br />
shotcrete robot <strong><strong>an</strong>d</strong> each<br />
shotcrete crew used<br />
One heading per week <strong>for</strong> each<br />
shotcrete robot used<br />
Two p<strong>an</strong>els at each of ages 7<br />
<strong><strong>an</strong>d</strong> 28 days at start of project<br />
<strong>for</strong> one fibre type <strong><strong>an</strong>d</strong> dosage<br />
Two p<strong>an</strong>els at 28 days <strong>for</strong> each<br />
week of shotcrete production or<br />
at <strong>an</strong>y ch<strong>an</strong>ge in fibre type or<br />
dosage
<strong>Quality</strong> Assur<strong>an</strong>ce Pl<strong>an</strong><br />
<strong>Shotcrete</strong> <strong>Quality</strong> <strong>Control</strong><br />
– <strong>Shotcrete</strong> Materials Check List<br />
– Inspection <strong><strong>an</strong>d</strong> Test Pl<strong>an</strong> (ITP)<br />
a) Materials<br />
b) Batching <strong><strong>an</strong>d</strong> Supply<br />
c) Hardened <strong>Shotcrete</strong><br />
<strong>Shotcrete</strong> <strong>Quality</strong> Audit<br />
– Non-con<strong>for</strong>m<strong>an</strong>ce Report (NCR)<br />
– Opportunity <strong>for</strong> Improvement Report (OFI)<br />
– Corrective Action Report (CAR)<br />
– Audit Report
Conclusions<br />
Production of quality shotcrete in <strong>an</strong> underground<br />
environment requires:<br />
Rigorous shotcrete specifications<br />
Implementation of a quality m<strong>an</strong>agement pl<strong>an</strong><br />
(follow ISO 9000 approach)<br />
Pre-production qualification of all materials <strong><strong>an</strong>d</strong> shotcrete mixture<br />
design<br />
Implementation of a systematic quality control inspection <strong><strong>an</strong>d</strong><br />
testing pl<strong>an</strong> <strong>for</strong> the aggregates, mix water <strong><strong>an</strong>d</strong> plastic <strong><strong>an</strong>d</strong><br />
hardened shotcrete<br />
Use of nozzlemen <strong><strong>an</strong>d</strong> shotcrete batching, supply <strong><strong>an</strong>d</strong> application<br />
crew properly trained <strong><strong>an</strong>d</strong> qualified