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Shotcrete is often used for the construction and stabilization of tunnels and other underground structures, where it is susceptible to different forms of physical and chemical attacks affecting its durability. An advanced understanding of the factors that limit the durability of shotcrete is crucial to develop tailored strategies for enhancing its service life. The main focus of this contribution is to shed light on the durability of shotcrete by revising the literature, highlighting what is missing and needs to be addressed, assessing how the knowledge about concrete durability can be transferred to shotcrete, and providing recommendations for durable shotcrete structures. (C) 2018 Elsevier Ltd. All rights reserved.
Die Dauerhaftigkeit von Spritzbeton kann, insbesondere in seiner Verwendung als Stütz-und Ausbaumaterial im Tunnelbau, durch chemische Angriffe deutlich herabgesetzt werden. Im Forschungsprojekt "Entwicklung neuer dauerhafter und nachhaltiger Spritzbetone (ASSpC)" wurden Prüfkörper von Trocken-und Nassspritzbetonen in Großspritzversuchen hergestellt. Der Sulfatwiderstand und das Lösungsverhalten der Betone in sulfathaltigen wässrigen Lösungen wurden mit drei Testverfahren bestimmt und die Ergebnisse miteinander verglichen: Ein Pulvertestverfahren zeigt die Auflösung von Zementhydratphasen zugunsten der Neubildung von Calcit und Ettringit. Das Ausmaß der Sulfatdehnung an Bohrkernen, ermittelt im zweiten Testverfahren, korrespondiert mit dem chemischen Verhalten des gemahlenen Materials, insbesondere bezüglich der Reaktivität von calcium-und aluminium-haltigen Hydratphasen. Der Thaumasitwiderstand, ermittelt über Masseverlust von Prüf-körpern, zeigte eine weitgehende Übereinstimmung mit den zuvor genannten Tests. Die Verwendung von hochreinen Metakaolinen (7-10 M-% des Bindemittels) oder Feinstcalcit (5-10 M-% des Bindemittels) allein führte insgesamt zu deutlich geringerer Sulfatbeständigkeit. Hingegen konnten hohe Gehalte an Hüttensand oder Silikastaub auch in Kombination mit Metakaolin und Feinstcalcit den Sulfatwiderstand von Spritzbeton erhöhen.
The durability of shotcrete can be degraded by chemical attacks, especially if used as ground support in tunnel construction. In the course of the research project "Advanced and Sustainable Sprayed Concrete (ASSpC)" test specimens of dry-mix and wet-mix shotcrete were sprayed in large-scale tests. The sulfate resistance and the leaching behaviour of these shotcretes were assessed in sulfate-bearing solutions. A test procedure based on the use of shotcrete powders shows that hydrated cement phases dissolve in favour of calcite and ettringite neo-formation. The sulfate expansion measured on drill cores in the second procedure corresponds to the behaviour of the powders, especially regarding the reactivity of calcium-and aluminium-bearing hydrated phases. The resistance against thaumasite attack, assessed by measuring the mass loss of prisms, coincides with the former test results. The exclusive use of high-purity metakaolin (7-10 wt-% of binder) or fine calcium carbonate (5-10 wt-% of binder) leads to a decrease in the sulfate durability. However, high amounts of blast furnace slag or silica fume can increase the sulfate resistance of shotcrete even when used in combination with metakaolin or fine calcium carbonate.
Although the number and size of interconnected pores have been identified as the most important aspects of concrete microstructure, comprehensive datasets on shotcrete porosity and pore size distributions are still scarce and their key controls are poorly investigated. In this study we investigate the effects of the spraying process, setting accelerator addition and mix design on the microstructure of real-scale dry- and wet-mix shotcrete and hand-mixed and sprayed accelerated pastes. A newly proposed deconvolution analysis of the pore size distributions, measured by mercury intrusion porosimetry, offers increased precision in determining the critical and median pore diameter parameters. In total >50 samples were analysed. Results show that the dry-mix shotcrete exhibits a shift towards coarser pore sizes (∼100–1 μm) than wet-mix shotcrete. Combinations of different supplementary cementitious materials are favourable for producing wet-mix shotcretes with refined pore structures. The addition of setting accelerators, up to 10 wt-% of binder mass, and the spraying process cause systematic variations in the pore volume and pore structure of (sprayed) paste and shotcrete.
Shotcrete is a material frequently used in underground constructions such as tunnels, where Ca leaching and sulfate attack are important durability issues. In this study, two test methods were employed to investigate the sulfate resistance and leaching behaviour of dry- and wet-mix shotcretes in sulfate solutions on a time-resolved basis. Tests on powdered samples showed the dissolution of AFm, portlandite and C-A-S-H, subsequently followed by the precipitation of calcite and ettringite. The extent of sulfate expansion of drill cores corresponded to the chemical response of the powder materials, particularly on the reactivity of Ca- and Al-containing hydrated cement phases. The use of high-purity metakaolin (7-10 wt%) in the shotcrete binder significantly decreased the sulfate durability, while high amounts of other SCMs such as blast-furnace slag and silica fume (> 20 wt%) had a positive effect on the durability of shotcrete.