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Improved understanding of the mechanisms underlying deleterious chemical attacks is necessary to better predict the long-term performance and durability of shotcrete in aggressive environments. In the scope of the research project “ASSpC - Advanced and Sustainable Sprayed Concrete”, new durable and sustainable shotcretes and new test methods are developed. In order to increase shotcrete durability, the spray cement (specified in Austrian Guideline “Sprayed concrete”) used is substituted with supplementary cementitious materials (SCMs). However, in the past SCMs have seen only limited use in the application of dry-mix shotcrete. This contribution presents 6 new mix designs intended to be used for dry-mix shotcrete, each with varying amounts and types of SCMs, and compares their performance and sprayability with a commercially available spray cement. As sulfate attack is one of the major threats to shotcrete (e.g. in tunnelling), the resistance of the new mixes against sulfate attack is tested using a modified version of the Swiss sulfate test according to SIA 262/1:2013. This approach provides new insights into damaging mechanisms of dry mix shotcrete in sulfate-loaded environments
Before new mixes are sprayed in real scale applications, lab experiments have to be carried out to provide a basis for predicting a good performance in real scale. In many cases, to understand the correlations between the behavior in the lab and in real scale spraying, a further set of experiments after the real spraying is required. In this paper we present such a two way process for two new wet mixes, one with a very low tricalcium aluminate Portland cement and the other one with a CEM I with addition of ultra-fine calcite. Calorimetry and Shear-Modulus measurements were used in the lab to monitor hydration evolution. In the real scale spraying compressive strength was measured at periodic intervals up to 24 hours. The hydration of the sprayed samples was stopped at 3, 6 and 24 hours and samples were scanned with X-ray for the identification and quantification of the phases present. The results presented are used to discuss the extent to which lab experiments can predict the behavior of mixes in real scale and how small changes in the raw materials and the mixes can lead to quite different results.
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.
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.