Slope Stabilisation and the Beauty Of Shotcrete AN OVERVIEW

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1 Slope Stabilisation and the Beauty Of Shotcrete AN OVERVIEW Matthew Hicks Managing Director The RIX Group EAGCG Shotcrete Seminar May

2 OVERVIEW History Types of Shotcrete Equipment Specifications and Guides Versatility Current Issues Limitations Finishes The Good, The Bad and The Ugly EAGCG Shotcrete Seminar May

3 History 1907 Carl Akeley invented the first dry spray machine 1930 s American Railway Engineering Association introduces the term SHOTCRETE to describe the Gunite Process EAGCG Shotcrete Seminar May

4 Hand Spraying Then & Now Hand Spraying 1930 s And Now EAGCG Shotcrete Seminar May

5 HISTORY 1950 s Shotcrete first reported used in Australia for slope stabilisation and refractory lining Wet Mix Introduced 1960 s Tunnels sprayed Snowy Hydro Scheme and Shotcrete used for Swimming Pools Remote controlled shotcrete equipment introduced ACI adopts the term SHOTCRETE to describe Pneumatically applied mortar and concrete wet and dry 1970 s Steel Fibre introduced Norwegians start to use remote controlled equipment and steel fibre on a large scale s Sandy Hollow Rail Tunnel, NSW and the increased use of Shotcrete for basement shoring walls, slope stabilisation, ground support in mines, shafts and tunnels. EAGCG Shotcrete Seminar May

6 Further Developments 1987 First Australian shotcrete guide (CIA) Sprayed Shotcrete 1990 s The use of Robotic Equipment for overhead spraying introduced & rapidly increased 2000 s Structural Macro synthetic fibres came into vogue in Australian mines & some Civil projects Tele Remote Shaft lining introduced st Edition of Guide to Shotcreting in Australia Published nd Edition of Guide to Shotcreting in Australia Published 2016 RMS 2 nd edition of Design guideline to improve the appearance of shotcrete 2017 Approx 250,000m3 of shotcrete sprayed in Australia, 60% in underground mines and 40% in civil & construction application EAGCG Shotcrete Seminar May

7 Types of Shotcrete Dry or Wet Hand sprayed or Robotically applied Plain With Steel Reinforcement or Fibre Reinforced Finished or Unfinished EAGCG Shotcrete Seminar May

8 Aspect Wet Mix Dry Mix Equipment Mixing Lower maintenance cost, Higher capital cost. Accurate mixing at plant can utilise bulk premix. Wet aggregates acceptable Higher maintenance cost, Lower capital cost. Mixing at site, plant or premix. Performance can be impaired by wet aggregates. Range limited to max 6% moisture content. Output Rebound Moderate to high placement (3-10m3/hr hand held or 25m3/hr remote control) Low Rebound, typically 5-15% Depending on mix design and application Low to Moderate placement (1-1.5m3/hr) Generally higher rebound that wet (Up to 30%) depending on site conditions and applicator Dust Low Dust Notably higher dust than wet mix In place quality Consistent Potential for higher variability Pumping distance Low, generally no more that 100m unless special lines and mixes are used High, Up to 500m with special equipment EAGCG Shotcrete Seminar May

9 EQUIPMENT Dry Spray Pump Wet Spray Pump EAGCG Shotcrete Seminar May

10 Underground Shotcrete Rigs Robotic Overhead spraying Tele Remote Shaft liner EAGCG Shotcrete Seminar May

11 Specifications and Guides AUSS CIA 2010 Recommended practice Shotcreting in Australia - V2 Specification for Shotcrete finishes To be incorporated into next RMS shotcrete design guide RMS R68 Shotcrete without steel fibre B82 Shotcrete work R64 Soil nailing Design Guidelines to approve the appearance of shotcrete TMR MRTS03 Drainage retaining structures and protective treatments ACI Specification for Shotcrete EFNARC European Specification for sprayed Concrete EAGCG Shotcrete Seminar May

12 Versatility EAGCG Shotcrete Seminar May

13 Shotcrete is ideal for Overhead application for ground support in mines and tunnels Vertical application for shoring, slopes and walls High, difficult and remote access areas Extremely cost effective compared to formwork Almost any shape can be achieved Architectural finishes Swimming pools, rock and water features, sea walls, culverts, retaining walls, slope stabilising, dome houses and structures. EAGCG Shotcrete Seminar May

14 Overhead & Underground Tunnels and Mines Hand Sprayed Robotically sprayed EAGCG Shotcrete Seminar May

15 Shotcrete TBM sets Airport Link EAGCG Shotcrete Seminar May

16 Embankment Stabilisation Spray from boom finish from Ropes Finished Abutments EAGCG Shotcrete Seminar May

17 Slope Stabilisation From Ropes Ropes and Cranes to Prep Ropes to Spray EAGCG Shotcrete Seminar May

18 Stabilisation Options in Harmony Drilling at Height Rock Fall Mesh and Shotcrete EAGCG Shotcrete Seminar May

19 Stabilisation Options in Harmony Forty Bends EAGCG Shotcrete Seminar May

20 Soil Nail Walls Clem 7 Cycleway Limited Access Simulated Rock Geelong Ring Road EAGCG Shotcrete Seminar May

21 Shoring walls for basement car parks Soldier piles, capping beam and ground anchors used in conjunction with shotcrete, retaining a vertical excavation EAGCG Shotcrete Seminar May

22 Dam Spillways EAGCG Shotcrete Seminar May

23 Structural rail culverts Bowen QLD EAGCG Shotcrete Seminar May

24 Screeded shotcrete walls for stone facing EAGCG Shotcrete Seminar May

25 Sea Walls EAGCG Shotcrete Seminar May

26 Sea Walls EAGCG Shotcrete Seminar May

27 Simulated Rock Melbourne Convention Centre Zoo Walkway EAGCG Shotcrete Seminar May

28 Swimming pools & Water features Sprayed Pool Garden EAGCG Shotcrete Seminar May

29 Sydney white-water kayak stadium EAGCG Shotcrete Seminar May

30 Shotcrete has a bad reputation Why? Lack of Specification or awareness of finishes required Poor Training, applications & care Poor mixes Poor compaction and finish Poor marketing of product and thus awareness EAGCG Shotcrete Seminar May

31 THE GOOD THE BAD AND THE UGLY EAGCG Shotcrete Seminar May

32 The Bad EAGCG Shotcrete Seminar May

33 The ugly EAGCG Shotcrete Seminar May

34 Is Shotcrete a Very Naughty Boy???? No - So who is? Perhaps; Those who designed it Those who didn t plan it Those who made it Definitely those who delivered it Probably all of the above because they didn t care about it But NOT SHOTCRETE and here s why EAGCG Shotcrete Seminar May

35 Good gun finish EAGCG Shotcrete Seminar May

36 Good screed & gun finish EAGCG Shotcrete Seminar May

37 Good wood float & sponge finish EAGCG Shotcrete Seminar May

38 Shotcrete Rockwork - Taronga Zoo Gorilla s a fan And the Seals are too EAGCG Shotcrete Seminar May

39 NWRL/NRT 20,000m2 24,000m Perm Nails EAGCG Shotcrete Seminar May

40 What has been done & what should be done Australian shotcrete guide Rev2 AUSS Presents shotcrete specification to RMS Possible upgrades to RMS B82 Spec RMS Rev update Shotcrete Guideline to approve appearance of shotcrete Increased awareness through industry seminars & Marketing Increased training MORE UPFRONT PROJECT TESTING Trials, Mixes, Personnel, Equipment UNLTIMETELY more and more examples of successfully finished projects EAGCG Shotcrete Seminar May

41 Before and After Leave it like this? Or like this? EAGCG Shotcrete Seminar May

42 Before and After EAGCG Shotcrete Seminar May

43 Test Panels should replicate the ACTUAL site conditions EAGCG Shotcrete Seminar May

44 K2RQ Rail Bridge Deflection walls Test Panels EAGCG Shotcrete Seminar May

45 K2RQ Finished deflection Walls EAGCG Shotcrete Seminar May

46 Fibres and Shotcrete Spraying, Pumping & Finishing LIMITATIONS Certain Grades of Finish Shotcrete is shotcrete, concrete is concrete cousins not twins - you can t ask one to be the other Tunnel/mine overhead mixes for Hand spraying You should not have to use structural Fibre over reinforcement You don t need to spray a meshed embankment with a tunnel mix Hand spraying is NOT robotic spraying Remote areas Extreme heights, no roads, limited access, distance from plants Economics where rock is present consider other options Rock fall mesh or matting EAGCG Shotcrete Seminar May

47 THE GOOD And THE BEUTIFAL EAGCG Shotcrete Seminar May

48 Worlds Largest Swimming Pool Chile EAGCG Shotcrete Seminar May

49 Dome House Miami This house was the only one in its street to survive cyclone Ivan in 2004 EAGCG Shotcrete Seminar May

50 Pierre Cardins house French Riviera EAGCG Shotcrete Seminar May

51 Crooked House Poland EAGCG Shotcrete Seminar May

52 The Guggenheim NYC EAGCG Shotcrete Seminar May

53 And in Australian we have - EAGCG Shotcrete Seminar May

54 Big Merino EAGCG Shotcrete Seminar May

55 THANK YOU EAGCG Shotcrete Seminar May