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Shotcrete or sprayed concrete in tunneling in connection with the "New Austrian Tunneling Method” has been developed over the last decades to reach a high quality standard. However, at present the development of new shotcrete mixes is required to fulfill durability and stainability requirements, i.e. for superior performance in aggressive environments and reduction of maintenance costs. In the course of the project ASSpC ("Advanced and sustainable sprayed concrete") the research team focuses on producing and testing new and innovative shotcrete mixes using local and environmentally friendly raw materials. Sustainable and durable shotcrete with optimized mechanical and physical properties and improved chemical resistance is developed.
This paper outlines the motivation for the project, gives an overview of the project structure and introduces key reaction mechanisms and environmental controls causing damage of shotcrete in tunnels.
The reduction of clinker use is mandatory to lower the negative environmental impact of concrete. In shotcrete mixes, similarly to the case of conventional concrete, the use of supplementary cementitious materials (SCMs) and proper mix design allow for the substitution of clinker without compromising the mechanical properties. However, the impact of the substitution on the durability of shotcrete needs to be further assessed and understood. The results from the present study, obtained from real-scale sprayed concrete applications, show a reduction of the Ca2+ leaching and sintering potential of clinker-reduced shotcrete mixes due to the presence of SCMs. This positive effect, crucial for low maintenance costs of tunnels, is mainly related to a reduced portlandite content, which on the other hand negatively affects the carbonation resistance of shotcrete. Additionally, the hydration of SCMs positively influences the chloride penetration resistance presumably due to a combination of microstructural changes and changes in the chloride binding capacity. Differences found in the pore size distribution of the various mixes have low impact on the determined durability parameters, in particular compared to the effect of inhomogeneities produced during shotcrete application.