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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

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