Specification - Tunnel Shotcrete Lining

Cv
Thiess John Holland

Joint Venture
Airport Link | Northern
Busway | EWAG
GL - Supplementary
Specification - Tunnel Shotcrete Lining
GLTSP102
Document ref
BC-PBA-GLTSP102SPC-0001-1-03
26 May 2010
DCN: 00047
IFA / AFC
Thiess John Holland

Joint Venture
Airport Link | Northern
Busway | EWAG
GL - Supplementary
Specification - Tunnel Shotcrete Lining
GLTSP102
May 2010
Parsons Brinckerhoff Arup Joint Venture ABN 88 642 968 608

Parsons Brinckerhoff Australia Pty Ltd ABN 80 078 004 798
Arup Pty Ltd ABN 18 000 966 165
Copyright 2008 Thiess Pty Ltd, John Holland Pty Ltd,
Parsons Brinckerhoff Australia Pty Ltd, Arup Pty Ltd
Parsons Brinckerhoff Arup Joint Venture
Level 6 515 St Paul's Terrace, Fortitude Valley QLD 4006, PO Box 3546 South Brisbane BC QLD
4101
Tel +61 7 3309 7500 Fax +61 7 3309 7890
This report takes into account the

particular instructions and requirements
of our client.
It is not intended for and should not be
relied upon by any third party and no
responsibility is undertaken to any third
party
Job number
A125840
PB2108209A
Document Verification
Page 1 of 1
Airport Link | Northern Busway | EWAG
Job title
Job number
PB2108209A A125840
Document title
GL - Supplementary Specification - Tunnel - Shotcrete Lining

GLTSP102
Document ref
BC-PBA-GLTSP102-SPC-0001-1-03
Revision
Date
AFC Issue 25/02/09
26 May 2010
Filename
BC-PBA-AGTSP100-SPC-0002-0-01.doc
Description
AFC Issue
Name
File reference
Prepared by
Checked by
Approved by
Andreas Amon
Robert Bertuzzi
Eddie Woods
Signature
Review
16/02/10
Filename
BC-PBA-GLTSP102-SPC-0001-1-01.doc
Description
Issued for Review, DCN: 00047, Refer to Table 2
Name
Prepared by
Checked by
Approved by
Eddie Woods
Richard Page
Eddie Woods
Signature
Review
29/03/10
Filename
Description
Issued for External Review, DCN: 00047, Refer to Table 2
Name
Prepared by
Checked by
Approved by
Eddie Woods
Richard Page
Eddie Woods
Signature
IFA / AFC
26/05/10
Filename
Description
Issued for IFA / AFC, DCN: 00047, Refer to Table 2
Name
Prepared by
Checked by
Approved by
Eddie Woods
Richard Page
Eddie Woods
Signature
Issue Document Verification with Document
C:\APL-PBAJV\KIERAN.COOK\DMS47695\BC-PBA-GLTSP102-SPC-0001-1-03.DOC
26 May 2010

IFA / AFC 26 May 2010
Thiess John Holland Joint Venture

GL - Supplementary Specification - Tunnel - Shotcrete Lining GLTSP102
Contents
1
Page
1
General
1.1
Scope
1.2
Definition of Terms
1.3
Standards and Related Specifications
1.4
Discrepancy Between Drawings and Specification
1.5
Changes to previous revisions
1.6
Records Maintained by the Contractor
Quality System Requirements
2.1
General
2.2
Hold Points, Witness Points and Milestones
2.3
Work Method Statements
10
2.4
Testing Frequency
10
2.5
QDMR Registered Suppliers and Products
10
Shotcrete Materials
11
3.1
General
11
3.2
Shotcrete Types
11
3.3
Water
11
3.4
Cement
11
3.5
Supplementary Cementitious Materials
12
3.6
Aggregates
12
3.7
Alkali-Aggregate Reaction (AAR)
14
3.8
Admixtures
14
3.9
Fibres
16
3.10
Soluble Salts (permanent shotcrete only)
17
Shotcrete Requirements
17
4.1
Construction Method Statements
17
4.2
Mix
18
4.3
Acceptance Testing and Field Trials
18
4.4
Sprayed Concrete Trials
19
4.5
Submission Details
21
4.6
Performance
21
Surface Preparation for Shotcrete Application
22
5.1
Preparation of Rock Surfaces
22
5.2
Preparation of Shotcrete / Concrete Surfaces
23
5.3
Preparation for Installation of Waterproof Membrane
23
Application of Shotcrete and Curing
26 May 2010
24

6.1
Equipment
24
6.2
Proficiency of Nozzlemen
25
6.3
Production and Transport
25
6.4
Application
26
6.5
Thickness and Profile Control
27
6.6
Curing
28
Shotcrete Testing
28
7.1
Production Tests
28
7.2
Compressive Strength Test
30
7.3
Flexural Toughness Test
31
7.4
Dry Density, Boiled Absorption and Voids Volume
31
7.5
Fibre Content
31
7.6
Slump
32
7.7
Test of Steel Fibre
32
Repair of Shotcrete
32
8.1
General
32
8.2
Core Hole Repair
32
Remedial Works to Non-Conforming Shotcrete
32
9.1
General
32
9.2
Compressive Strength Failures
33
Tables
Table 1 Definition of Terms
Table 2 Changes made to previously issued revisions
Table 3 Hold Points
Table 4 Witness Points
Table 5 Milestones
Table 6 Work Method Statements
Table 7 Items Requiring Use of QDMR Registered Suppliers and Products
Table 8 Aggregate Grading for Shotcrete
Table 9 Maximum Dosages of Accelerator
Table 10 Maximum Values of Acid-Soluble Chloride-Ion Content in Shotcrete
Table 11 Particular Mix Requirements
Table 12 Testing Methods Field Trials
Table 13 Minimum Performance Requirements for Shotcrete
Table 14 Test Methods Production Testing for Temporary Shotcrete Lining
Table 15 Test Methods Production Testing for Permanent Shotcrete Lining
Appendices
Appendix A
Verification Records
Appendix B
Response to Comments
26 May 2010


General
This technical specification has been provided by Parsons Brinckerhoff Arup Joint Venture
on behalf of Thiess John Holland Joint Venture for use in execution of the Design and
Construct Contract with the Airport Link, Northern Busway and ARU project (the Project).
1.1
Scope
This specification supersedes Shotcrete Lining (reference AGTSP100-0002).

This Specification applies to the manufacture, supply and application of shotcrete for the
temporary and permanent (pump sumps and substations) shotcrete lining of the Airport Link
and Northern Busway tunnels. In addition, this document specifies the performance based
requirements for shotcrete and details the testing requirements to ensure that the shotcrete
applied on site is consistent with these performance requirements.
For this Project, shotcrete is concrete with or without admixtures pneumatically applied to a
prepared rock surface, in and around steel sets, or in and around lattice girders.
The scope of this Specification comprises:
steel or synthetic fibre reinforced shotcrete (SFRS),
steel mesh reinforced shotcrete
and plain or unreinforced shotcrete (URS)
plain shotcrete with polypropylene fibres to provide fire protection
aggregates for use in permanent shotcrete requiring fire resistance
The specification covers both temporary works shotcrete and permanent shotcrete. The
specification complies with the Mined Tunnels Design Manual and will be reviewed and
updated as necessary during execution of the Works.
The types of shotcrete for underground works are as follows:
SFRS applied as temporary (initial) and permanent (pump sumps and substations)
ground support
URS applied as a smoothing layer prior to installation of the tunnel waterproofing

membrane or providing an initial layer in combination with mesh reinforcement prior to
application of permanent lining or as a finishing layer for permanent ground support
(pump sumps and substations).
This Specification shall be read in conjunction with the Temporary and Permanent Works
Design Drawings and other relevant Specifications. The thickness dimensions shown on the
Drawings are minimum thicknesses. Shotcrete thicknesses shall be such as to provide a
minimum cover, as shown on the Drawings, over all steel components and fixtures including
rockbolt heads, steel sets, lattice girders and reinforcing mesh.
The General Specification (reference BC-PBA-GLRSP000-SPC-0001) provides general
information relating to all other specifications. The General Specification must be used with
this Specification.
Users of this Specification and related specifications and documents are required to ensure,
that they are referring the current version.
The durability of shotcrete manufactured in accordance with this specification has been
assessed in the Durability Report (reference PBA-BC-AGDTR100-RPT-0001).
This specification is to be read in conjunction with the related specifications outlined in
Clause 1.3.
C:\APL-PBAJV\KIERAN.COOK\DMS47695\BC-PBA-GLTSP102-SPC-0001-103.DOC
26 May 2010
Page 1

1.2

Definition of Terms
Definitions applicable to many specifications, including this Specification, shall include those
found in the General Specification (reference BC-PBA-GLRSP000-SPC-0001).
While the definitions found in the General Specification take precedence, the following
definitions, when not found in the General Specification, apply particularly to this
Specification:
Table 1 Definition of Terms
Term
Definition
Relative Strength for

Silica Fume
The relative strength for silica fume is the ratio (in percent) of the
compressive strength of standard mortar bars, prepared with 90% cement
plus 10% silica fume by mass, to the compressive strength of standard
mortar bars made from cement only.
Admixtures
Materials added to base concrete such as accelerators and hydration

control mixtures. (Note that silica fume, plasticisers and retarders may be
included in Base Concrete if proposed to be used in the Temporary and
Permanent Works shotcrete).
Cement
An active hydraulic binder formed by grinding clinker and conforming to AS

3972. Cement and cementitious content exclude the mass of silica fume.
Characteristic
Cylinder strength at
28 days
The value of the standard cylinder strength at 28 days below which 5% of

the population of all possible strength measurements are expected to fall.
(Characteristic cylinder strengths are quoted in the Specification for the
purpose of the development of mix design only).
Curing
The control of temperature and moisture in the concrete until the concrete
has developed required properties.
Flash Coat
Sprayed concrete applied as a thin layer protecting, priming or finishing the

surface of the tunnel. A flash coat shall be at least 20mm thick.
In Situ Cylinder
Strength
The notional strength of shotcrete at a single location, considered as the

strength of a cylinder of shotcrete as it exists in the structure. In situ cylinder
strengths are given in the Specification for the purpose of compliance
requirements.
Lattice Girder
A lightweight, three dimensional steel or fibreglass frame made to act as a

unit by connecting all components with lacing bars; used in conjunction with
shotcrete for shotcrete lining reinforcement.
Layer
A discrete thickness of sprayed concrete built up from a number of passes

of the nozzle which is allowed to set.
Nozzle
Attachment at end of delivery hose from which shotcrete is projected.
Overspray
Material projected outside the intended receiving surface.
Rebound
Shotcrete which having passed through a spraying nozzle does not adhere
to the surface to which shotcrete is being applied.
SFRS
Steel fibre reinforced shotcrete
Silica Fume Concrete
Concrete manufactured by combining cement complying with AS 3972 with

silica fume. The Contractor shall ensure that sufficient lime is available for
reaction with the silica fume, particularly when sulphate resistant cement or
pulverised fuel-ash is used.
Sloughing
Subsidence of fresh shotcrete.
Shotcrete
A mixture of cement, aggregate, and water projected at high velocity from a
26 May 2010
Page 2


Term
Definition
nozzle into place to produce a dense, homogeneous mass, applied directly
to the ground surface in one or more layers to form the lining of a sprayed
concrete support structure.
Shotcrete Type S1
Steel fibre reinforced shotcrete (SFRS) which is applied as initial or primary

ground support and is designed to carry temporary loads only.
Shotcrete Type S2
Steel mesh reinforced shotcrete (SMRS) which is applied as initial or

primary ground support and is designed to carry temporary loads only.
Shotcrete Type S3
Un-reinforced shotcrete (URS) which is applied as initial or primary ground

support and is designed to carry temporary loads only.
Shotcrete Type S4
Un-reinforced shotcrete (URS) which is applied as backfill shotcrete,

smoothing shotcrete and/or as a protective layer to shotcrete Type S1, P1
or bare rock, and is designed to carry temporary loads only.
Shotcrete Type P1
SFRS which is applied as permanent ground support and is designed to

carry permanent loads.
Shotcrete Type P2
SMRS which is applied as permanent ground support and is designed to

carry permanent loads.
Shotcrete Type P3
Plane shotcrete used as a smoothing layer and to provide fire protection
Shotcrete Mix Terms
Base Mix: Concrete designed, tested and supplied independent from the
shotcreting process, equipment and personnel.
Shotcrete Mix: The base mix after it is applied to the Works, or to test
panels.
Sprayed Concrete
Support Systems
Structure
A structure built underground in accordance with this specification.
Standard Cylinder
strength
The measured compressive strength of a cylinder made, cured and tested

in accordance with AS 1012.8 and AS 1012.9 for cast samples and in
accordance with AS 1012.14 for cored samples.
URS
Unreinforced Shotcrete
Waterproofing
Supervisor
As defined in the Waterproofing and Drainage Specification (reference BCPBA-GLTSP107 SPC-0001).
Wet-mix Process
The process of producing shotcrete in which cement and aggregate are

weigh batched and mixed with water at or near the shotcreting location or in
mixer trucks prior to being pumped through a pipeline to a nozzle where
compressed air, and admixtures if necessary, are injected and the mix
projected into place without interruption.
1.3
1.3.1
General Specification
The General Specification (reference BC-PBA-GLRSP000-SPC-0001) contains information
required for an understanding of any and all of the specifications applicable to the Project.
The General Specification shall be read prior to use of any of the other specifications,
including this Specification.
1.3.2
This specification is to be read in conjunction with the following:
PBAJV SS
26 May 2010
Page 3


BC-PBA-GLTSP101-SPC-0001 Global Supplementary Specification Tunnel - Rock

Reinforcement
BC-PBA-GLTSP102-SPC-0001 Global Supplementary Specification Tunnel - Mined
Tunnel Excavation and Implementation
BC-PBA-GLTSP106-SPC-0001 Global Supplementary Specification Tunnel Cast in
Place Concrete
BC-PBA-GLRSP009-SPC-0001 Global Supplementary Specification Road Projectwide
Instrumentation and Monitoring
BC-PBA-GLTSP107-SPC-0001. Global - Supplementary Specification Waterproofing and
Drainage
BC-PBA-AGDTR100-RPT-0001 Durability Technical Report
PSTS
PSTS01
Introduction to Technical Standards
PSTS03
Drainage, Retaining Structures and Protective Treatments
PSTS50
Specific Quality System Requirements
PSTS70
Concrete
PSTS71
Reinforcing Steel
Australian Standards
AS 1012
Methods of Testing Concrete
AS 1141
Methods for Sampling and Testing Aggregates
AS 1379
Specification and Supply of Concrete
AS 1478.1
Chemical Admixtures for Concrete
AS 2350
Methods of Testing Portland and Blended Cements
AS 2758.1
Aggregates and Rock for Engineering Purposes Concrete Aggregates
AS 3582.1
Supplementary cementitious materials for use with Portland and blended

cement Fly Ash
AS 3582.2

cement Slag Ground Granulated Iron Blast Furnace
AS 3582.3

cement Silica Fume
AS 3583.6
Methods of test for supplementary cementitious materials for use with

portland cement
AS 3972
Portland and Blended Cements
AS/NZS 4671
Steel Reinforcing Materials
AS/NZS ISO 9001 Quality Management Systems Requirements

ASTM Standards
ASTM A820
Standard Specification for Steel Fibres for Fibre-Reinforced Concrete
ASTM C1260
Standard Test Method for Potential Alkali Reactivity of Aggregates

(Mortar-Bar Method)
ASTM C1550
Standard Test Method for Flexural Toughness of Fibre Reinforced

Concrete (Using Centrally Loaded Round Panel)
26 May 2010
Page 4


ASTM C311
Standard Test Methods for Sampling and Testing Fly Ash or Natural
Pozzolans for Use in Portland-Cement Concrete
ASTM C94
Standard Specification for Ready-Mixed Concrete
British Standards
BS EN 1367-2
Tests for Thermal and Weathering Properties of Aggregates
BS EN 14488-4
Testing sprayed concrete. Bond strength of cores by direct tension
BS EN 14488-7
Testing sprayed concrete. Fibre content of fibre reinforced concrete
BS EN 14889-1
Fibres for concrete - Part 1: Steel fibres - Definitions, specification and

conformity
BS EN 14889-2
Fibres for concrete - Part 2: Polymer fibres - Definitions, specification and

conformity
Other Standards
ACI 506R-05
Guide to Shotcrete
Specification for Tunnelling, British Tunnelling Society and the Institution of Civil Engineers
ITA-shotcrete guidelines, Sprayed concrete for final linings: ITA working group report,
AITES / ITA, 2001
Concrete Institute of Australia, Recommended Practice Shotcreting in Australia
1.4
Discrepancy Between Drawings and Specification
Where a discrepancy exists between the Design Drawings and this Specification the
Contractor shall seek clarification from the Construction Certifier. Drawing notes will take
precedence over the Specification.
1.5
Changes to previous revisions
The following table details all the changes made to this specification since previously issued
revisions.
Table 2 Changes made to previously issued revisions
Revision
Clause
Change
Description
Description
1-01
General
Modification
Paragraphs and lists numbered for ease of

referencing
DCN:
00047
Section 1 Sections reorganised inline with the

new specification template.
1.1
Modification
Minor text changes clarifying scope
1.1
Modification
Addition of last 2 bullet points to first set of bullet

th
points, First sentence of 5 paragraph added, and
additional text added to the last bullet point in
second set of bullet points.
1.2
Modification
Activity Index for Silica Fume has been amended to

Relative Strength, SFRS definition added,
Shotcrete Type P3 definition added and URS
definition added.
1.3
Addition
Addition of reference AS 3583.6
1.5
Addition
Section added in Table 2 to specify all changes in
26 May 2010
Page 5


the report.
3.2
Modification
Addition of the final bullet point added
3.5.2 a)
I.
Deletion
Text deleted (undensified)
3.5.2
Modification
I,vi changed from Silica activity index to relative

strength and reference added.
3.6 v.
Addition
Text added For aggregates comprising volcanic

breccia, mudstone, shale, sandstone, weathered or
altered rocks
Bullet Points added
3.6
Modification
Table 8 revised. S3 put in column one for %

passing and S4 replaces S3 for % passing.
3.8.2 e)
Addition
Text added The Contractor shall test selected

types of accelerators for the range of 2% in 5.0%,
8.0% dosages or the manufacturers recommended
dosage to ensure the short and long term strength
is not impaired and meets the specified
requirements
3.10
Addition
Text added (permanent shotcrete only)
4.1
Addition
Section 4.1 Inserted
4.2
Modification
Witness point added

Section moved from Section 4.1 to 4.2
4.3 vi.
Addition
Text added (for permanent shotcrete only)
4.4. ( b)
Modification
Text modified and added The target slump(s)

shall be determined by trial mixes with and without
superplasticisers provided the pre production and
production tests show that the sprayed concrete
achieves the short and long term strengths
specified in Table 13 for field tests and production
tests (cores), for sprayed concrete the target slump
shall be;
Addition
Without superplasticiser: 80 to 120mm

With superplasticiser: 80 to 150mm
4.4.( i)
Addition
Text added (a spare specimen shall be taken but

not tested)
4.4 (n)
Addition
Text added The Contractor shall provide 1,7,28

& 90 day strength verses time curves for cores
taken directly from the tunnel lining together with
early strength results (less than 1 day) for beam
end test verses needle penetrometer tests
4.6
Modification
Table 13 updated
Field trials and Production Tests (Cylinder) updated
Dry density 2150 to 2400Kg/m
- for permanent shotcrete only added to Boiled
Absorption and Apparent Volume
26 May 2010
Page 6


Note (1) added clarifying purpose of maximum

strength
Addition of Fire Performance of P3 shotcrete row
5.3
Addition
(a) text added in first paragraph

Clause 5.3.1 Smoothing Shotcrete section added
6.3 f)
Addition
Text added however, using a drop pipe to

transfer the concrete from the surface underground
into an agitator truck is acceptable provided the
material does not become overly segregated and
remixing produces a homogenous sprayable mix.
7.1
(Table
14)
Modification
Requirement for 1 day tests deleted (as covered by

beam end tests)
Compressive strength test changed to a cylinder
sample
Deletion of Boiled Absorption and Voids Volume
7.1
(Table
15)
Modification
Requirement for 1 day test deleted as covered by

Early age compressive strength test
Compressive strength test changed to a cylinder
sample
Boiled absorption test required for permanent
shotcrete only
Flexural strength test method added.
1-02
1.1
Addition
Addition of text The durability of shotcrete..
1.2
Modification
Definition of Silica Fume Concrete has been

modified. Wording used now has been modified
from comment response for clarity.
1.2
Addition
Addition of Waterproofing Supervisor definition
1.3
Addition
Addition of references to Waterproofing and

Drainage specification and Durability Report.
3.6
Modification
Table 8 updated P3 added into column
3.8.2
Modification
Addition of text But shall not exceed
3.8.4
Modification
Part C changed to include P3
3.9
Addition/Modification
Structure changed around to include new headings.

3.9.1 General, 3.9.2 Steel Fibres etc.
DCN:
00047
26 May 2010
Page 7

1.6

4.2
Modification
Addition of column to Table 11 of P3
Table 11
Modification
No change to content but Table has been

reformatted for clarity.
4.4 b
Modification
Determined has been replaced with confirmed
5.3
Addition
Addition of text as required by the

Waterproofing.
5.3.1
Deletion
Deletion of 5.3.1 Part b part iii.
5.3.1
Modification
Text modified to say manufacturers
6.1
Addition
Addition of P3 to 1st paragraph
General
Modification
Where items have been shown for the approval of

the Designer, this should have referred to the
Construction Certifier. This general error has been
corrected throughout the document.
General
Modification
Formatting and grammatical errors have been

amended for the IFA / AFC issue.
Records Maintained by the Contractor
a) General guidelines for records are provided in the General Specification (reference BCPBA-GLRSP000-SPC-0001).
b) Records of work methods, listed in Table 6 related to this specification are required to
be submitted by the Contractor to the Construction Certifier in accordance with the
quality system requirements of the Contract.
c) This Specification requires the Contractor to prepare and maintain, as a minimum, the
following documents in accordance with the Contractors Project Quality Plan and make
them available for audit purposes:
i.
Proposals to adopt alternative materials and equipment
ii.
All information necessary to produce as-built drawings and records
iii. Details of cement for shotcrete, including suppliers details and information to
demonstrate compliance with AS 3972
iv. Details of fly ash, slag and silica fume for shotcrete
v.
Details of aggregates and aggregate sources for shotcrete, including testing and
properties of the aggregates
vi. Manufacturers test certificates and product analysis certificates for the fibres to be
used for the fibre reinforced shotcrete
vii. Test results for the water used in the mixing and curing of the shotcrete
viii. Concrete Suppliers batch card showing details of the mix design for each type of
shotcrete
ix. Details of all admixtures for shotcrete, including manufacturers product data, and
the equipment and method of controlling the addition of admixtures to the shotcrete
x.
Records of the type of equipment used for batching, mixing, transport and
application of shotcrete, including location of the batching plant and method of
delivery to site
26 May 2010
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xi. Results of all acceptance testing and field trials, and results of production testing of
the shotcrete
xii. The mix design for each type of shotcrete shall be approved by the Construction
Certifier.
xiii. Records of inspection and written approval of the Temporary and Permanent Works
shall be provided in accordance with this Specification.
Quality System Requirements

2.1
General
a) Specific quality system requirements are detailed within PSTS50. Construction

activities shall be carried out in accordance with the provisions of the Contractors
Quality System which shall comply with the requirements of AS/NZS ISO 9001.
2.2
Hold Points, Witness Points and Milestones
a) The Hold and Witness Points particular to this Specification are listed in Table 3, Table
4 and Table 5 below. Refer General Specification (reference BC-PBA-GLRSP000-SPC0001) for Hold Point, Witness Point and Milestone definitions and requirements.
b) The Contractor shall not proceed beyond a Hold Point until the Hold Point has been
released by the person nominated in Table 3. The Contractor shall notify the relevant
person when a Hold Point will be reached so that they can review and/or witness any
work process, record or test being undertaken by the Contractor and thus expedite the
release of that Hold Point.
Table 3 Hold Points
Specification Clause
Hold Point Details
For Release By
All relevant Hold Points outlined in the

Specifications and Project Deed including the
hold points referred to in the QDMR Project
Specific Technical Standards (PSTS) as
described in Annexure 10 Part 1
IV
Hold Points as the Contractor deems

necessary to meet its obligations under the
Deed.
Contractor
4.3
Approval of shotcrete mix designs and mix

trials (pre-construction tests) including the
proposed curing regime
Construction Certifier
6.2
Certification of nozzlemen
Contractor
Repair of shotcrete
Remedial works to non-conforming shotcrete
c) The Contractor shall provide the person nominated in Table 4 reasonable notice
(minimum 24 hours or as otherwise specified) of all Witness Points so that inspection
may be made of the following:
Table 4 Witness Points
Specification
Clause
Witness Point Details
For Release By
Witness Points as the Independent Verifier deems

necessary to meet its obligations under the Deed.
IV
Witness points as the Contractor deems
Contractor
26 May 2010
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Specification
Clause
Witness Point Details
For Release By
necessary to meet its obligations under the Deed.

4.1/4.3
5
6.5
Trial Mixes / Field Trials
Surface preparation complete (rock, concrete or

waterproofing)
Final surface within tolerance
d) The Contractor shall submit at the time nominated in Table 5, documentary evidence of
Milestones to the Construction Certifier for approval of materials and workmanship as
specified throughout the Specification.
Table 5 Milestones
2.3
Milestone Details
Timing
4.1
Construction Method Statement
30 days prior to
commencement of work
4.3
Submit proposed shotcrete mix designs
30 days prior to
4.3
Submit results of field trials
30 days prior to
Work Method Statements which are required to be submitted by the Contractor to the
Construction Certifier in accordance with the quality system requirements of the Contract
are listed below in Table 6.
Table 6 Work Method Statements
4.1
2.4

Construction Method Statement for Tunnel Shotcrete Placement
Testing Frequency
The minimum testing frequency for work covered by this Specification is specified in
Clause 7.
2.5
QDMR Registered Suppliers and Products
The use of QDMR registered suppliers and products for the construction of the project
works are required for the items listed in Table 7.
Table 7 Items Requiring Use of QDMR Registered Suppliers and Products
3.4
Category of Work
Cement Supply
3.5.1
Fly Ash
3.5.2
Silica Fume
3.8
Admixtures
26 May 2010
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Shotcrete Materials
3.1
General
Materials for shotcrete as a minimum must conform to the requirements of this Clause of the
Specification.
3.2
Shotcrete Types
The following shotcrete mixes are specified for this project:

a) Shotcrete Type S1: Steel fibre reinforced shotcrete for temporary support of
excavations. The characteristic cylinder strength of Shotcrete Type S1 at 28 days is
40 MPa.
b) Shotcrete Type S2: Steel mesh reinforced shotcrete for temporary support of
excavations. The characteristic cylinder strength of Shotcrete Type S2 at 28 days is
40 MPa.
c) Shotcrete Type S3: Unreinforced shotcrete for temporary support of excavations. The
characteristic cylinder strength of Shotcrete Type S3 at 28 days is 40 MPa.
d) Shotcrete Type S4: Un-reinforced shotcrete for infilling voids and smoothing of surfaces.
The characteristic cylinder strength of Shotcrete Type S4 at 28 days is 25 MPa.
e) Shotcrete Type P1: Steel fibre reinforced shotcrete for permanent support of
excavations. The characteristic cylinder strength of Shotcrete Type P1 at 28 days is
40 MPa.
f)
Shotcrete Type P2: Steel mesh reinforced shotcrete for permanent support of
excavations. The characteristic cylinder strength of Shotcrete Type P2 at 28 days is
40 MPa.
g) Shotcrete Type P3: Plain Shotcrete shall have monofilament polypropylene fibres in
accordance with Section 3.9. The characteristic cylinder strength of Shotcrete Type P3
at 28 days is 40 MPa.
3.3
Water
a) Water incorporated into shotcrete shall be potable, free from contaminants harmful to
concrete or reinforcement and have electrical conductivity not exceeding 1000 microsiemens/metre.
b) Water to be used in the manufacture of shotcrete for the Temporary and Permanent
Works shall be of an acceptable quality as defined in Clause 2.4 of AS 1379.
c) Water used for curing, testing water tightness or for other purposes where it may come
in contact with shotcrete, shall be potable, clean and free from oil and suspended
matter, and shall otherwise comply with the requirements of Clause 2.4 of AS 1379.
3.4
Cement
a) Cement shall be Type GB or GP in accordance with AS 3972.

b) All blended cement shall contain not more than 15% Fly Ash. The final blend shall be
nominated by the Supplier or selected during field trials.
c) Cement older than three months from the date of dispatch from the manufacturer's
holding silos shall not be used for the Temporary and Permanent Works.
d) All mixes shall contain a minimum mass of Portland cement equal to 55% of the total
mass of cementitious material.
e) Test certificates for the cement showing suppliers details and demonstrating
compliance with AS 3972 used shall be maintained for audit purposes. The test
26 May 2010
Page 11


certificates shall cover the period from at least 12 months prior to commencement of the
project. Testing of cement properties in accordance with AS 3972 shall be carried out at
least monthly.
f)
Cementitious products shall be supplied only by a QDMR Registered Cement Supplier.
3.5
Supplementary Cementitious Materials
3.5.1
Fly Ash
a) Supplementary cementitious materials Fly Ash and Slag shall comply with AS 3582
Parts 1 and 2 respectively and shall be a QDMR registered fly ash or slag, with the
following modifications:
i.
The amount of fly ash retained when wet sieved on a 45 micron sieve shall not
exceed 15% by weight.
ii.
Loss on ignition to be not more than 4% by weight.
iii. Specific gravity shall not vary by more than 5%. The uniformity of specific gravity
shall be determined in accordance with Section 17 of ASTM C311.
3.5.2
Microsilica (Silica Fume)
a) Supplementary cementitious material Silica Fume shall comply with AS 3582 Part 3.
Silica fume is a latent hydraulic binder which shall comply with the following
requirements:
I.
Silica Fume/Dry Powder

i.
Bulk density not exceeding 650kg/m3
ii.
Silica content shall be not less than 85%
iii. Carbon content of silica fume shall be less than 5%

iv. Particle size shall be between 0.1 and 0.2 microns
v. Fineness: specific surface area shall not be less than 15,000m2/kg
vi. Relative Strength >95% after 28 days. Testing shall be in accordance with
AS3583.6
vii. Moisture content <3%.
II. Silica Fume/Water Slurry
i.
pH shall be 5.5 1.0
ii.
Water content shall be 50% 2%
iii. Relative density shall be between 1.3 and 1.4.

b) Testing to establish compliance with (I) and (II) above shall be carried out once prior to
work commencing and repeated annually during production for each supplier.
c) Silica fume/water slurry shall be regularly agitated by circulation pumps prior to use.
d) The compatibility of silica fume and liquid admixtures shall be established by either:
i.
Verification of existing test data, or
ii.
Carrying out appropriate accelerated testing procedures
e) The Contractor shall maintain details of silica fume used in shotcrete for audit purposes.
3.6
a)
Aggregates
In addition to the requirements of this Specification, aggregates for shotcrete shall be

supplied from a quarry which holds QDMR certification (which shall be correct at the
date of supply) and comply with AS 2758.1 as indicated below:
26 May 2010
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i. The nominal maximum particle size shall be 10mm unless approved otherwise by the
Construction Certifier.
ii.
The Los Angeles coefficient shall be determined in accordance with sub clause 10.2
of AS 2758.1
iii. The magnesium sulphate soundness value determined in accordance with BS EN

1367-2 shall not exceed 18.
iv. The water absorption of the aggregate determined in accordance with AS 1141.6
shall not exceed 2%.
v.
For aggregates comprising volcanic breccia, mudstone, shale, sandstone,

weathered or altered rocks the drying shrinkage of the aggregate determined in
accordance with AS 2758.1 shall not exceed 0.075%.
vi. The fines content less than 75 micron determined in accordance with AS 1141.12
shall not exceed 2%.
vii. The aggregate shall be tested for reactivity with the cementitious materials and
admixtures (including accelerators) using the ASTM C1260-01 accelerated mortar
bar method.
viii. Single size aggregates shall be combined in the proportions determined during the
field trials. The individual fractions shall be stored separately.
b)
Coarse and fine aggregates shall be free from earth, clay loam and soft clayey, shaley
or decomposed stone, organic matter, friable particles and other impurities and shall be
hard and dense. The grading shall be within the acceptable range according to the
grading given in Table 8 below for wet mix shotcrete.
c) The grading and moisture content of the individual fractions of the aggregate shall be
checked and recorded at least weekly.
d) The Contractor shall maintain for audit purposes details of aggregates and aggregate
sources for shotcrete, including testing and properties of the aggregates.
e) The following aggregates have been tested and confirmed as suitable for use with
polypropylene fibres for permanent shotcrete requiring resistance to fire:
Bromelton North Olivine Basalt,
Beenleigh Meta-Greywacke,
Petrie Greenstone
Narangba Hornfelsed Greenstone.
f) Should the contractor wish to use other aggregates these will require further testing.
26 May 2010
Page 13


Table 8 Aggregate Grading for Shotcrete

Sieve Size
3.7
Percent Passing by Weight

S1, S2, S3, P1, P2 and P3
S4
9.5 mm
90 100
6.70 mm
80 90
90 100
4.75 mm
70 85
75 90
2.36 mm
50 70
50 75
1.18 mm
35 55
35 55
600 m
20 40
20 40
300 m
8 20
8 20
150 m
2 10
2 10
75 m
02
02
Alkali-Aggregate Reaction (AAR)
a) Aggregates intended for use in shotcrete shall not react with alkalis in the concrete that
may result in excessive expansion. The aggregate supplier must provide documentation
of the potential reactivity of the aggregate in accordance with PSTS70 clause 11.1. The
proposed concrete mixes shall meet the innocuous classification of QDMR Test Method
Q458.
3.8
Admixtures
3.8.1
General
b) Admixtures for the purposes of this Specification shall not be used without the approval
of the Construction Certifier.
c)
Admixtures shall conform to the requirements of AS1478 and shall be a QDMR

registered admixture.
d) Admixtures to the sprayed concrete mix shall be stated in the Method Statement. The
performance of the modified mix shall be demonstrated by site trials prior to that mix
being used in the Works.
e) All admixtures for shotcrete shall be sourced from a single manufacturer or supplier
where possible to ensure compatibility of admixtures for use in the shotcrete. Where
admixtures are sourced from different suppliers, evidence shall be obtained to
demonstrate the compatibility of the admixtures. Compatibility of all admixtures with
each other and with all other sprayed concrete constituents shall be verified during site
trials.
f)
The Contractor shall obtain sufficient documentation to support the use of all admixtures
prior to commencement of field trials. The documentation shall include the
manufacturers product data and details of the equipment and method for controlling the
addition of admixtures to the shotcrete.
g) Confirmation of the following requirements for all admixtures shall be obtained by the
Contractor from the manufacturer prior to use in the tunnels and shafts:
i.
Confirmation that admixtures are free of chlorides
ii.
Arrangements for ensuring the consistency of supply and delivery of admixtures to

the batching plant
26 May 2010
Page 14


iii. Variations in the characteristic values of the properties of each admixture

iv. Conditions for storage and handling of admixtures
v.
Confirmation of the stability of admixtures with the mix water
vi. Results of testing as required by this Specification for each type of admixture
vii. Confirmation that the additives are safe to use in a tunnel environment and any
safety precautions that are to be taken
3.8.2
Accelerators
a) Accelerators are admixtures. Only liquid accelerators shall be used.
b) Sodium Silicate (Waterglass) shall not be used.
c) Only the minimum quantity of accelerator necessary shall be permitted in normal
shotcreting operations. The quantity shall be determined by field trials, subject to the
maximum dosages specified in Table 9:
Table 9 Maximum Dosages of Accelerator
Shotcrete Type
By weight of cementitious material
S1
8%
S2
8%
S3
8%
S4
8%
P1
5%
P2
5%
P3
5%
d) Testing of accelerators in accordance with this Specification with regard to acceleration

of setting, early strength, and decrease of strength at a later age (28 and 90 days), shall
take place in due time before commencement of shotcrete application.
e) The Contractor shall test selected types of accelerators over a range of 2% for 5.0% or
8.0% dosages (See Table 9) but shall not exceed the manufacturers recommended
dosage to ensure the short and long term strength is not impaired and meets the
specified requirements. Laboratory testing of the selected type(s) of accelerator shall
be carried out in accordance with this Specification at dosages of 5.0% and 8.0% for
non-caustic, alkali free accelerators by weight of cementitious material in the base
concrete, or similar dosages as recommended by the manufacturer, to establish the
variability of the above properties with dosage. Accelerators showing excessive
variability with dosage will not be permitted.
f)
Accelerators shall be selected such that, at the dosage chosen for use, the decrease in
strength of any Shotcrete Type at an age of 28 days, compared with the base concrete
without any accelerators, shall not exceed 25%. Also, there shall be no further
reduction in strength of the shotcrete mix between 28 and 90 days. Compliance with this
clause shall be demonstrated by testing at a frequency as deemed necessary.
3.8.3
Plasticisers and Retarders
a) Plasticisers and retarders are admixtures and shall comply with AS 1478 and may be
used in Shotcrete Types S1, S2, S3, S4, P1, P2 and P3 subject to the approval of the
b) Plasticisers and retarders may be used to reduce the quantity of the mixing water and to
improve the pumpability of the shotcrete. The effects and optimum dosages of
26 May 2010
Page 15


plasticisers and retarders shall be determined during development of the mix design
and/or by field trials in accordance with this Specification.
c) Plasticisers and retarders shall not contain calcium chloride.
d) Compatibility of plasticisers and retarders with cements, latent hydraulic binders and
accelerators shall be verified by observation during development of the mix design
and/or in the field trials.
e) Plasticisers and retarders shall be used in accordance with the manufacturers
instructions.
Hydration Control Admixtures
3.8.4
a) Hydration control admixtures may be used with Shotcrete Types S1, S2, S3, P1, P2 and
P3 in accordance with this Specification and subject to the approval of the Construction
Certifier. Hydration control admixtures used with accelerator in Shotcrete Type S1, S2,
S3, S4, P1, P2 and P3 shall not cause a decrease in strength with age.
b) Hydration control admixtures may be used to control the hydration of the mix as
appropriate to expedite construction of the Temporary and Permanent Works. The
effects and optimum dosages of hydration control admixtures shall be determined by
field trials in accordance with this Specification.
c) Hydration control admixtures that delay the setting process by greater than 10 hours for
Shotcrete Type S1, S2, S3, S4, P1, P2 and P3 shall not be used. Proposals to use
hydration control admixtures for longer periods may require additional field trials and/or
testing as specified by the Construction Certifier.
d) Compatibility of hydration control admixtures with cements, latent hydraulic binders and
accelerators shall be verified by observation in the field trials.
e) Hydration control admixtures shall be used in accordance with the manufacturer's
instructions.
3.9
Fibres
3.9.1
General
a) Fibres may be collated with fast-acting water-soluble glue, or may be uncollated
individual fibres. Water-soluble glue or other additives used to collate fibres shall be
compatible with other shotcrete components.
b) Fibres shall be stored in dry sealed containers until ready for use and shall be free from
corrosion, oil, grease, chlorides and deleterious materials which may reduce the
efficiency of mixing or spraying processes, or which may reduce the bond between the
fibres and the shotcrete. Containers of fibres shall be stored in areas protected from the
weather and extremes of heat as per the manufacturers instructions.
c) Fibre type shall be selected on the basis of compliance with this Specification and on
suitability and ease of use in the batching, mixing and shotcreting processes proposed,
as demonstrated by field trials. Fibres which tend to form fibre balls during batching and
mixing shall not be used.
3.9.2
Steel Fibres
a) Steel fibre shall be deformed steel fibre Type 1, 2 or 3 in accordance with ASTM A820
except that Type 1 fibre may be either circular or rectangular in section. Fibres shall be
produced from milled steel or cold drawn wire and shall be ungalvanised.
b) Steel fibres shall have an aspect ratio in the range of 30 to 150. Tolerances shall be in
accordance with ASTM A820.
26 May 2010
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3.9.3
Synthetic Fibres (Structural)
a) Synthetic fibres shall be of the structural macro-synthetic type of fibre in accordance
with BS EN 14889-2 and of greater than 0.3mm diameter. The fibre shall have a
textured surface and be produced from polyolefin or a similar base resin material. .
Synthetic Fibres (Fire)
3.9.4
a) Synthetic Fibre may be used in Shotcrete Type P1, P2 or P3 to achieve the specified
design requirements for the fire load case.
b) Micro-synthetic fibres shall be 18-32 micron monofilament PP fibres specifically

manufactured for use as a concrete additive and so certified by the manufacturer, and
containing no reprocessed olefin materials.
c) Alternative monofilament PP fibre dimensions may be proposed provided they have test
data to demonstrate they have equivalent fire performance criteria as the 18-32 micron
fibres.
d) The required dosage and effectiveness of fibres in reducing concrete spalling due to
exposure to fire shall be assessed by the Concrete Fire Testing Specification (reference
BC-PBA-GLSSP414-SPC-0001).
3.10
Soluble Salts (permanent shotcrete only)
a) The chloride ion content of the hardened shotcrete must be tested in accordance with
AS1012.20. A representative sample of at least 20 grams of crushed and ground
shotcrete shall be used, with the titrating solution being 0.01 to 0.02N. For the test, use
the Volhard method calibrated using a concrete with known chloride content.
b) The mass of acid-soluble chloride ion per unit volume of permanent shotcrete as placed
must not exceed the values given in Table 10.
c) The sulphate content of shotcrete, determined by calculation and expressed as the
percentage by mass of acid-soluble SO3 to cement, must not be greater than 4.0%.
Table 10 Maximum Values of Acid-Soluble Chloride-Ion Content in Shotcrete
Maximum acid-soluble chloride ion content (kg/m)
Exposure *
Classification
Fibre Reinforced Concrete or Conventional Reinforced Concrete
0.8
B1
0.8
B2
0.8
Note: Chloride ion content may be expressed in percentage weight of oven dried concrete.
(0.1 kg/m3 ion content is approximately equivalent to 0.004% by weight of oven dried
concrete). *For information on exposure classifications see AS 5100.5.
Shotcrete Requirements
4.1
Construction Method Statements
a) A Construction Method Statement for the tunnel shotcrete lining works shall be
prepared prior to commencing any work. The method statement is to be submitted for
review to the Construction Certifier at least 30 days prior to the commencement of
temporary or permanent shotcreting works Milestone. The Construction Method
Statement shall contain, as a minimum, full details of the following where appropriate:
i.
Methods of working
ii.
References to Safety Plan and Quality Assurance procedures
iii. Names of responsible persons

26 May 2010
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iv. Proposed methods for Surface Preparation

v.
Proposed methods for use of steel reinforcement and other embedments where
applicable
vi. Proposed methods and equipment for mixing, conveying and applying shotcrete
vii. Details of procedures for monitoring of shotcrete thickness, including spacing of
depth indicators (if applicable) and details of how the profile is to be maintained.
viii. Repair procedures, including proposed mix designs for core hole repair
4.2
Mix
a) Mix designs shall comply with the requirements shown in Table 11. Witness Point.
Table 11 Particular Mix Requirements
Shotcrete Type
Parameter
S1
S2
S3
S4
P1
P2
P3
Steel Fibre
- minimum tensile strength (MPa)
900
N/A
900
N/A
- minimum length (mm)
25
N/A
25
N/A
50
N/A
50
N/A
30
N/A
30
N/A
- maximum length (mm)

3
- minimum content (kg/m )

Cementitious Material
Type GP or GB** with microsilica
Minimum Cementitious Content

(kg/m)
400
Maximum Water * : Cementitious

Content Ratio
0.45
Accelerator Type
Non-caustic, alkali free
Silica Fume Content
5-10%
(4-8% when used with Type GP or GB)
* Water shall include the liquid content of liquid admixtures

** Fly ash content not to exceed 15% by weight. Care should be taken in the choice of cementitious
materials to ensure that sufficient lime is available for reaction with the silica fume.
b) Shotcrete shall be applied by the wet mix process and be capable of being applied in
layers up to 150 mm in thickness with good adhesion to the ground or previous layers of
shotcrete without sagging or slumping.
c) Shotcrete shall be dense and homogeneous without segregation of aggregate and/or
fibre or other visible imperfections.
4.3
Acceptance Testing and Field Trials
a) The purpose of the field trials is to check the suitability of the proposed mix design,
materials, plant, the work methods and the competence of the shotcrete operators.
Sprayed panels shall be used to verify the following design properties:
i.
Compressive strength;
ii.
Density;
iii. Fibre content;

iv. Shrinkage (for permanent shotcrete only);
v.
Permeability (for permanent shotcrete only);
26 May 2010
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vi. Flexural strength (for permanent shotcrete only); and

vii. Flexural Toughness.
b) Field trials shall be started sufficiently early to ensure that the required shotcrete mixes
are developed and all trials completed satisfactorily by the time shotcreting of each
Shotcrete Type commences in the Temporary and Permanent Works. Shotcreting of
any Shotcrete Type shall not commence until the relevant trials have been completed,
and the results of the field trials and acceptance testing submitted to the Construction
Certifier for approval at least 30 days prior to the commencement of Shotcreting Hold
Point 1 Witness Point Milestone.
c) The field trials shall employ the types of equipment which will be used in the Temporary
and Permanent Works and the constituent materials shall be fully representative of
those to be used in the Temporary and Permanent Works.
d) Each field trial shall be a witness point with a notice period of three (3) days.
e) As an alternative to field trials the Contractor may adopt a proven shotcrete mix design
with a test history of at least 12 months that demonstrates compliance with the
requirements of this Specification to be submitted for approval Milestone.
f)
If field trials are required, testing for field trials shall be in accordance with Table 12.
Table 12 Testing Methods Field Trials

Test
Method
Compressive Strength (cast sample)

Compressive Strength (cored sample)
AS 1012.8 and AS 1012.9

AS 1012.14
Flexural Toughness (Round Panels SFRC Only)
ASTM C1550-03a
Fibre (SFRC only)
This Specification
4.4
Sprayed Concrete Trials
a) From the field trial mix an experienced nozzleman shall prepare sufficient test panels.
Panels for coring shall be at least 1000 x 1000mm in size and shall be 200mm thick.
The panels shall be prepared by shotcreting into rigidly supported vertical moulds.
Moulds shall be constructed of steel or other non-water absorbing rigid materials. The
upper and lower edges of the mould shall have parallel sides splayed outwards at 45
degrees to the back face to prevent the entrapment of rebound. The vertical edges of
the mould shall have parallel sides at 90 degrees to the back face to facilitate coring
perpendicular to the spray direction. Round panels for flexural toughness testing shall
be 800 10mm diameter and 75 15mm thick, and prepared by shotcreting into rigidly
supported vertical moulds in accordance with ASTM C1550-03a. In all cases, the
shotcrete in panels shall adhere well to the backform, be properly compacted and
exhibit no sagging.
b) The target slump(s) shall be confirmed by trial mixes with and without superplasticisers.
The pre production and production tests on sprayed shotcrete shall comply with the
short and long term strengths specified in Table 13 for field tests and production tests
(cores). For sprayed concrete the target slump shall be;
Without superplasticiser: 80 to 120mm
With superplasticiser: 80 to 150mm
c) All panels shall be protected immediately against moisture loss using the same method
to be used in construction, shall not be moved for 18 hours after spraying, and shall be
stored without disturbance until the time of coring, sawing, or testing. Cores for 1, 7, 28
and 90 day compressive strength tests shall be obtained from the panels at 22hours.
26 May 2010
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The cores for 7, 28 and 90 day strength tests shall be stored in water in accordance
with AS 1012. Round panels for flexural toughness testing shall be stored in water in
accordance with AS 1012.
d) Cylindrical test specimens shall be cored from each test panel and tested as listed
below. Drilling of test specimens shall be in accordance with AS 1012.14. Drilling of
cores shall be located to avoid areas of possible rebound. No two cores to be tested at
any given age shall come from the same panel. Cores to be tested at different ages (i.e.
1, 7 and/or 28 days) may come from the same panel. For each test at least one spare
specimen shall be provided. The testing requirements and core dimensions shall be:
i.
Compressive strength in spray direction after 1, 28 and 90 days on 4 cores each.

The prepared test cores shall be 75mm diameter and 150mm long (minimum).
ii.
Compressive strength perpendicular to spray direction after 1, 7, 28 and 90 days on

4 cores each. The prepared test cores, to be taken from different panels, shall be 75
mm diameter and 150 mm long (minimum).
e) Each cored cylinder or round determinate panel shall be marked with an appropriate
reference mark and the date and time of shotcreting.
f)
Steel fibres used shall have a minimum tensile strength of at least 900 MPa
g) Setting times shall be observed during the field trials in accordance with BS EN 196-3.
h) Optimum fibre content shall be determined dependent on ease of use in the batching,
mixing, and shotcreting processes proposed, and from the results of the tests to
determine flexural toughness by the testing of round determinate panels.
i)
The compressive strength of shotcrete cores from test panels shall be acceptable if the
compressive strength results both for samples with their axes parallel to the direction of
spraying and for samples with their axes perpendicular to the direction of spraying,
comply with the minimum performance requirements set out in this Specification. One
test result shall consist of the mean of three core strengths (a spare specimen shall be
taken but not tested). Seven day results shall be used for indicative purposes only. The
compressive strength of cores in steel fibre reinforced or plain shotcrete shall be
deemed to be the in situ cylinder strength provided that the specified requirements are
met in terms of core diameter and height: diameter ratio.
j)
A minimum of three successful Round Panels tests that meet the specification in Table
13 are required for each shotcrete mix.
k) The Contractor shall carry out such other tests and trials during the period of the field
trials as may be necessary, to confirm that proposed mixes and methods meet the
minimum performance requirements and particular mix requirements of this
Specification.
l)
The field trials shall be repeated if the source or qualities of any of the materials or the
mix proportions are required to be changed during the course of the Temporary and
Permanent Works.
m) For permanent quality shotcrete applications the durability of the sprayed concrete mix
shall be established by water permeability tests carried out on additional cores taken
from the panels
n) The Contractor shall provide 1,7,28 & 90 day strength verses time curves for cores
taken directly from the tunnel lining together with early strength results (less than 1 day)
for beam end test verses needle penetrometer tests
26 May 2010
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4.5

Submission Details
a) The Contractor shall submit details of each shotcrete mix design for approval to the
Construction Certifier at least 30 days prior to the commencement of shotcreting works.
The submission shall include, as a minimum, the following information:
I.
Mix Design
i.
The name of the concrete supplier and the proposed methods and degree of
quality control
ii.
Types and proportion by mass of various materials comprising the mix,

including chemical admixtures and supplementary cementing materials
iii. A copy of the Quarry Assessment Certificate for each material source
iv. Target strength
v.
Trial mix water/cement ratio and corresponding nominated water/cement ratio.
vi. Slump of the trial mix and corresponding nominated slump

II.
Trial Mix
i.
Number and sizes of test panels
ii.
Base mix used in each test panel
iii. Type and dosages of nozzle-added admixtures

iv. Required and actual thickness
v.
Description of finished product
vi. The degree of control required to achieve uniform shotcrete without excessive
rebound, sloughing, partial or total collapsing during shotcreting.
b) This constitutes a hold point for each different shotcrete mix used in the works covered
by this Specification.
4.6
Performance
The performance requirements are shown in the Table 13.

Table 13 Minimum Performance Requirements for Shotcrete
Parameter
Test Method or
Clause No
Shotcrete Type
S1
S2
S3
S4
P1
P2
P3
Min Mean Insitu Cylinder

Strength [MPa] +++
Field trials
and
Production
Tests
(Core)
at 1 day +
AS 1012.14
8MPa
at 7 days*
(cored
samples)
Field trials
and
Production
Tests
(Cylinder)
at 1 day +
AS 1012.8.1
8MPa
N/A
8MPa
at 7 days*
AS1012.9
25MPa
N/A
25MPa
at 28 days
(cylinder
samples)
40MPa
25MPa
40MPa
at 28 days
at 90 days ++
at 90 days ++
N/A
8MPa
20MPa
N/A
20MPa
32MPa
25MPa
32MPa
32MPa
Max In-situ Cylinder Strength
As above
32MPa
40MPa
40MPa
70MPa(1)
Flexural Toughness (Round

26 May 2010
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Determinate Panels)
at 1.0mm deflection
ASTM
12 J
at 5.0mm deflection
C1550-03a
62 J
62 J
at 20mm deflection
211J
211J
at 40mm deflection
282J
282 J
Dry Density
[All tests at 28 days]
N/A
12 J
AS 1012.8
2150 to 2400kg/m
AS 1012.21
8% max
AS 1012.21
17% max
N/A
Boiled Absorption (max. %)

[All tests at 7 days] (for
permanent shotcrete only)
Apparent Volume of
Permeable Voids (max. %)
[All tests at 7 days] (for
Early Age Compressive
Strength
Shrinkage Strain (for
Beam End Test

(**)
1.0MPa before personnel re-entry into heading.
AS1012.13
N/A
850 microstrain
after 8 weeks
drying
DIN1048
Part 5
N/A
25mm
maximum
penetration
Permeability (for permanent

shotcrete only)
Fire Performance of P3
shotcrete
Permanent shotcrete with 2kg/m3 dosage of

polypropylene fibres made from aggregates listed
in Section 3.6. A lower dosage may be
acceptable if fire tests using the same concrete
mix, fibres and aggregates meet the fire
performance requirements.
* Tests used for indicative purposes only.

** Refer to section 11.4.4 Concrete Institute of Australia, Recommended Practice Shotcreting in
Australia
+ Compressive Test at 1 day may be stopped depending on compliance and as approves by the
++ Compressive Tests at 90 days are only required if hydration control admixtures are included in the
shotcrete mix.
+++ The required minimum values of mean in situ cylinder strength require that testing shall be on
drilled cores in accordance with this Specification, i.e. 2:1 height: diameter ratio. No other height:
diameter ratio shall be used.
(1)
Maximum Strength is specified to avoid brittle failure of shotcrete. Exceptions may be approved on
a case by case basis through the RFI process.
Surface Preparation for Shotcrete Application

5.1
Preparation of Rock Surfaces
Before the application of sprayed concrete, the excavated surfaces shall be scaled by
mechanical hydraulic hammers or high-pressure hydro scaling to remove loose rock or
scats or shall be cleaned with compressed air and, as far as the local conditions permit, with
an air-water mixture as necessary to remove all material which may prevent proper
26 May 2010
Page 22


adhesion of the sprayed concrete to the excavated surface. The surface to receive shotcrete
shall be damp and without free water prior to application of sprayed concrete.
Action shall be taken as necessary to control ground water and prevent it adversely
affecting the sprayed concrete lining. Water inflows which might cause deterioration of the
concrete, or prevent adherence, shall be diverted by channels, chases, pipes or other
appropriate means to the invert or to the ground water drainage system.
Where necessary, pressure relief holes shall be provided through the primary lining to
ensure that no hydrostatic pressure develops behind the lining.
5.2
Preparation of Shotcrete / Concrete Surfaces
Existing shotcrete/concrete surfaces to be shotcreted shall be cleaned of any spalled,

cracked, deteriorated, loose, unsound and/or chemically contaminated shotcrete/concrete
until a sound and uncontaminated shotcrete/concrete is reached. Water blasting, chipping,
scabbling or other mechanical means shall be used to remove any contaminated shotcrete/
concrete Witness Point.
Where reinforcement is exposed, it should be free from loose rust, scale or other deleterious
matter likely to effect durability and bonding.
Where shotcrete is to be placed against a smooth concrete surface, the surface shall be
roughened by mechanical methods or by water blasting.
After the above preparation is carried out, the concrete surface shall be pre-wetted prior to
the application of shotcrete and any excess water shall be removed.
5.3
Preparation for Installation of Waterproof Membrane
a) Prior to fixing either a separation or waterproof membrane, a survey of the initial

shotcrete lining shall be performed to confirm the correct profile of the lining. Any
remedial measures required to correct out of tolerance profiles shall be undertaken in
accordance with approved Method Statements as required by the Waterproofing
Supervisor in accordance with specification (reference BC-PBA-GLTSP107-SPC -0001)
b) Where shotcrete is to be applied to a substrate comprising either a pre-formed sheet
membrane or a spray-on waterproof membrane the surface shall be prepared strictly in
accordance with the manufacturers recommendations and the relevant work method
statement. On no account shall SFRS be sprayed directly onto sheet membrane, unless
the membrane manufacturer can provide a guarantee that this will not damage the
membrane.
5.3.1
Smoothing Shotcrete (Type S4)
a) Smoothing shotcrete shall conform to the general requirements of PSTS04 with respect
to material and workmanship.
b) The tunnel shotcrete smoothing layer shall be in accordance with Design Drawings and
generally as follows:
i.
Shotcrete surfaces onto which a waterproof membrane is to be applied shall be

prepared by the addition of a shotcrete smoothing layer to remove local peaks and
infill hollows.
ii.
Surfaces on which waterproofing systems will be installed shall be clean, free from
loose aggregate, sharp protrusions, projecting tying wire, release agents and other
substances which are likely to damage or affect the waterproofing system.
iii. Not used.
26 May 2010
Page 23


iv. Large circumferential irregularities shall not exceed 200 mm when measure from a
1.0 m curved edge held against the tunnel circumference.
v.
Any curvature or irregularity shall have a radius greater than 200 mm.
vi. The shotcrete shall be cured for at least 24 hours prior to membrane application.
vii. Steel elements, such as reinforcement bars, steel fibres, steel girders and the
heads of rock bolts (as far as not used to hold inner lining structures) shall be
covered with at least 20mm of shotcrete.
viii. Running water ingress shall be plugged prior to the final lining. Heavy water ingress
can be collected into half-pipes (or flexi-drain or strip-drains or similar), mounted by
nailing and led into the permanent drainage system. The mounted half-pipe should
be covered with at least 20mm of shotcrete prior to the initial temporary works
shotcrete lining installation.
ix. Where water is found to be penetrating through the shotcrete lining at a rate that
may adversely affect the installation of membrane, the water shall be collected by
means of hoses and drained to the tunnel invert. The drainage shall be maintained
during the membrane installation process so that no water pressure can develop
behind the membrane.
x.
Inspection and acceptance shall be required in accordance with the approved

Contractors construction work method statement.
xi. The shotcrete smoothing layer shall be completed using a maximum aggregate size
of 4mm unless it can be demonstrated that a coarser aggregate can achieve a
surface compatible with the membrane manufacturers recommendations.
Shotcrete surface shall be at least 28 days old prior to the application of spray
applied membranes.
Application of Shotcrete and Curing

6.1
Equipment
a) Only wet mix process equipment shall be used for Shotcrete Types, S1, S2, S3, S4, P1,
P2 and P3. Equipment for the wet mix process shall be set up according to the
recommendations of the manufacturer. Pumping equipment shall ensure the continuous
conveyance of shotcrete at a steady and quantifiable rate with minimal pulsation. The
equipment shall allow for air and water in any combination to be available for
preparation of surfaces and/or cleaning of finished work in accordance with this
Specification.
b) All equipment used for batching and mixing of materials, and the transport and
application of all types of shotcrete shall be of suitable design and shall be maintained
in proper working order for the duration of excavation and lining works. The shotcrete
gun and ancillary equipment shall be of an adequate capacity for the volumes to be
applied, and shall be manufactured from suitable materials compatible with the
proposed accelerators and additives. A stand-by shotcrete system of plant and ancillary
equipment shall be available for the duration of excavation operations to ensure
shotcrete is available at all times to stabilise all exposed excavation faces. Air for the
equipment is to be clean, dry and oil free and to be provided at the equipment at not
less than the operating pressure and volume rates specified by the manufacturer.
c) Shotcreting equipment shall be capable of feeding materials at a regular rate and
ejecting shotcrete from the nozzle at velocities that will allow adherence of the materials
to the surface being shotcreted with a minimum of rebound and maximum adhesion and
density.
d) Equipment shall be leak proof with respect to all materials.
26 May 2010
Page 24


e) Equipment shall be thoroughly cleaned at least once per shift, or more frequently at
appropriate intervals if hydration control admixtures are used, to prevent accumulations
of residual deposits and/or deterioration due to the accelerators used.
f)
Transport pipes consisting of hoses or pipes shall be laid straight or in gentle curves.
The transport pipes shall have a uniform diameter appropriate to the mix and fibre
characteristics determined by field trials, and be free of any dents or kinks between the
shotcrete machine and the nozzle.
g) Equipment shall allow application of shotcrete to all surfaces with the nozzle at the
distances from the surfaces to be sprayed in accordance with this Specification.
h) Working areas for shotcreting shall be well illuminated. Cap lamps attached to safety
helmets will not be accepted as sufficient illumination. Dust pollution shall be minimised
by choice of appropriate equipment and by means of additional ventilation, water
sprays, and by maintaining equipment in good order.
i)
j)
Dosing of admixtures by hand is not permitted. Each machine provided for the wet mix
process shall incorporate:
i.
A memory programmable control system to coordinate and control all functions of

the machine including the dosing of all admixtures.
ii.
An integrated proportioning unit to dispense admixtures at the required dosages as

controlled by the throughput of concrete. The equipment shall be capable of
delivering admixtures such that the approved dosages are dispensed to an
accuracy of 0.5% of the required dosage and shall be calibrated and operated in
accordance with the manufacturer's instructions.
As far as practicable all shotcrete shall be applied using remote controlled spraying
equipment appropriate to particular applications. Hand spraying of wet mix shotcrete is
permitted.
k) Remote controlled spraying equipment shall be provided with as long reach as possible.
This shall ensure that the operator can observe the nozzle at all times during spraying
from a position of safety under supported ground. The controls shall provide the
operator with full and effective control of the nozzle articulation and other functions. The
equipment shall be used, cleaned and maintained in accordance with the
manufacturer's instructions.
6.2
Proficiency of Nozzlemen
a) Nozzlemen shall have had previous experience and be proficient in the application of
shotcrete. Production shotcrete shall be applied only by nozzlemen who have
demonstrated their competence and their ability to produce either plain or steel fibre
reinforced shotcrete by the method to be used. Nozzlemen shall hold certificates of
competence issued by the Contractor Hold Point 2.
6.3
Production and Transport
a) The individual components for the production of shotcrete shall be measured by weight
with an automatic batching device, except that admixtures may be measured by
volume. The batching accuracy shall be within 3% for all constituents except
admixtures (refer to Section 6.1.i.ii.). Silica fume shall be weighed separately. The
method of batching used shall ensure that the accuracy can be easily checked. All
measuring equipment shall be maintained in a clean and serviceable condition and shall
be zeroed daily and calibrated monthly.
b) Mixing shall be carried out in a mixer suitable for the efficient mixing and discharge of
wet batched materials.
26 May 2010
Page 25


c) Regular checks shall be made to ensure that complete mixing is routinely achieved.
Tests for mix consistency shall be in accordance with ASTM C94-04 or similar approved
international standard.
d) The addition of fibres shall be at a stage in the mixing suitable for the shotcreting
equipment. The procedure for the addition of fibres shall be determined during the field
trials. Fibres shall be added and mixed in a manner to avoid clumping and bending of
the fibres. Any fibre clumps in the mix shall be diverted and removed by means of a
screen placed over the shotcrete hopper. Fibres shall be uniformly distributed
throughout the mortar matrix without isolated concentrations. Fibres shall not be added
to the mix at a rate faster than that at which they can be blended with the other
ingredients without forming balls or clumps.
e) The mixed base concrete for the wet mix process shall be applied within one and a half
(1.5) hours of charging the mixer. This time may be extended by the use of retarders,
plasticisers or hydration control admixtures in accordance with this Specification.
f)
6.4
The base concrete for shotcrete produced by the wet mix process shall be transported
by truck mixers, concrete pumps or other suitable containers and shall prevent
segregation or possible loss or gain of water. Remixing of material shall not be
permitted, however, using a drop pipe to transfer the concrete from the surface
underground into an agitator truck is acceptable provided the material does not become
overly segregated and remixing produces a homogenous sprayable mix. The mixture
shall be effectively protected against any influence of the weather.
Application
The following requirements shall be achieved prior to and during the application of the
shotcrete:
a) Method statement and procedures have been submitted and approval has been given
by the Construction Certifier.
b) Checking and correction of the excavated cross section profile shall be carried out and
rock surfaces and/or existing shotcrete shall be cleaned with compressed air and, as far
as the local conditions permit, with an air-water mixture as necessary to remove all
material which may prevent proper adhesion of the shotcrete to the surface. The
surface to receive shotcrete shall be damp, but without free water prior to the
application of shotcrete. Treatment with an air-water mixture to ensure that the surface
is sufficiently clean and damp shall be done shortly before the application of shotcrete.
c) Action shall be taken to control groundwater and prevent it adversely affecting the
shotcrete lining. Adopted measures shall remain effective for at least 28 days. Water
inflows which might cause deterioration of the shotcrete, or prevent adherence, shall be
diverted as detailed on the Drawings, or otherwise proposed by the Contractor, by
channels, chases, pipes or other appropriate means, to the invert or to the temporary
groundwater drainage system.
d) Where necessary, pressure relief holes shall be provided through the primary lining to
ensure that no hydrostatic pressure develops behind the lining.
e) Ensure the thickness control devices are in place
f)
The distance between the nozzle and the surface to be shotcreted shall not exceed
1.8m for remote controlled spraying and 1.0m for hand spraying with the wet mix
process. The nozzle shall, as a general rule, be held perpendicular to the application
surface except as necessary to ensure proper embedment of steelwork such as lattice
girders where shown on the Drawings.
g) Depending on the required final thickness the application of steel fibre reinforced
shotcrete may be undertaken in two or more stages to minimise rebound, the first phase
being as stated on the Drawings.
26 May 2010
Page 26


h) Each layer of shotcrete shall be built up by making several passes of the nozzle over
the working area using good working practices and nozzle manipulation. The shotcrete
shall emerge from the nozzle in a steady uninterrupted flow. Should the flow become
intermittent for any cause the nozzleman shall direct it away from the work until it again
becomes constant.
i)
Where a layer of shotcrete is to be covered by succeeding layers, it shall first be

allowed to set and loose material and rebound shall be removed. The surface shall be
checked for soundness, repaired as specified, finally cleaned, and wetted using a blast
of air and water.
j)
No rebound material shall be covered with shotcrete. All rebound material shall be
removed from the working area and shall not be used in the Temporary and Permanent
Works. Disposal shall be undertaken with proper regard to the risks of environmental
pollution by both the cementitious materials and/or the admixtures.
k) For vertical and near vertical surfaces application shall commence at the bottom. Layer
thickness shall be governed mainly by the requirement that the material shall not sag.
Where thick layers are applied the top surface shall be maintained at a slope of
approximately 45 degrees. For overhead surfaces shotcrete shall preferably be applied
from the shoulder to the crown.
l)
Pockets, sags or other defects shall be cut out and resprayed. The area of respraying
shall not be less than 300mm x 300mm.
m) Unless specifically required and appropriate mixes designed, finishing actions, such as
trowelling or screeding, shall be avoided and may require remedial works to be
undertaken.
n) The temperature of the mix before spraying shall not be below 5C or above 35C
unless special provisions are made to the approval of the Construction Certifier.
Spraying shall not be undertaken when the ambient temperature is below 5C.
o) Sprayed concrete shall not be applied in the Temporary and Permanent Works until the
correct setting characteristics are observed during the start-up and a continuous
shotcrete stream is ejecting from the nozzle.
p) Where two layers of reinforcement are used, the far face reinforcement shall be covered
by sprayed concrete before the near layer is installed. The near layer shall be covered
by sprayed concrete up to the required thickness with the minimum delay.
6.5
Thickness and Profile Control
a) Where specified on the Drawings the minimum layer thickness shall be controlled by
depth pins attached to the rock bolt plates or lattice girders. Depth pins shall be used at
a frequency of at least one marker per 5m2 sprayed area. Where not specified on the
Drawings suitable thickness control measures shall be implemented by the Contractor
Witness Point.
b) Steel sets and/or other embedded steelwork shall be embedded as specified on the
Drawings.
c) Control of the profile of the shotcrete lining as shown on the Drawings shall be by
manual or electronic means. Laser based equipment shall comply with all necessary
local health and safety legislation and shall be used in accordance with the
manufacturer's instructions.
d) The shotcrete thickness shall be determined by surveying the tunnel section before and
after shotcrete application at intervals along the tunnel of not more than 5 m separation.
e) Tolerances are to be in accordance with those specified on the Design Drawings.
26 May 2010
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6.6

Curing
a) All final surfaces of shotcrete Types S1, S2, S3, S4, P1, P2 and P3 need not be subject
to special measures unless the results of testing indicate that the performance
requirements of this Specification are not being consistently achieved and that such
underperformance is attributable to poor curing, in which case the Contractor shall
make a proposal for curing the shotcrete for acceptance by the Construction Certifier.
Shotcrete Testing
7.1
Production Tests
b) Tests shall be carried out on a routine basis on cores or other samples taken from
shotcrete placed in the tunnels and shafts, or from panels prepared for test purposes.
c) Specimens shall be tested in accordance with the following clauses. The tests shall be
carried out as specified in Table 14 for temporary and Table 15 for permanent shotcrete
lining.
d) The frequency of carrying out each production test on specimens taken from shotcrete
placed in the tunnels and shafts is given in the following Clauses of this Specification.
The dimensions of test specimens shall be as specified elsewhere in this Specification.
e) Where cores are to be taken from the tunnels and shafts, and where the nominal
required shotcrete thickness is less than 100mm the cores for compressive strength or
other testing requiring specimens longer than 100mm shall be taken from areas where
the actual thickness is greater than 100mm. Alternatively, additional shotcrete thickness
shall be applied in selected areas for subsequent coring of test specimens.
26 May 2010
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Table 14 Test Methods Production Testing for Temporary Shotcrete Lining

Performance Criteria
Test Method
Test Frequency
One (1) for every 100m3 sprayed shotcrete.

Strength
Compressive Strength
(cored sample)
(cylinder sample)
Beam End Test
Minimum 1.0MPa compressive strength before

man entry. For each site one (1) test a day for
first two (2) weeks and afterwards one (1) test a
month.
3
For each 100m sprayed shotcrete three (3)
cores each for:
AS 1012.14
AS1012.8.1
AS1012.9
7day
28day
90day
For each 100m3 sprayed shotcrete three (3)
cylinder samples each for:
7day
28day
90day
Flexural
Toughness(Panels, SFRS
only)
ASTM C1550
Three (3) panels from the same shotcrete batch

for each 250m shotcrete
Dry Density (cored

sample)
AS 1012.12 and AS
1012.14
Three (3) tests on three (3) specimens from 7 or

3
28 day old shotcrete for each 250m
Dry Density (cast sample)
AS 1012.8
Three (3) tests on three (3) specimens from 7 or

3
28 day old shotcrete for each 250m
Fibre Content (SFRS

only)
BS EN 14488.7
One test (meaning the average of tests on 3

3
specimens) for each 250m
Slump
AS 1012.3 and AS
1379
For every 50m3 produced after the addition of

plasticiser for each load delivered.
26 May 2010
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Table 15 Test Methods Production Testing for Permanent Shotcrete Lining

Performance Criteria
Test Method
Test Frequency
One (1) for every 100m3 sprayed
shotcrete.

Strength
(cored sample)
(cylinder sample)
Beam End Test
Minimum 1.0MPa compressive strength

before man entry. For each site one (1)
test a day for first two (2) weeks and
afterwards one (1) test a month.
For each 100m3 sprayed shotcrete three
(3) cores each for:
AS 1012.14
AS1012.8.1
AS1012.9
7day
28day
90day
For each 100m3 sprayed shotcrete three
(3) cores each for:
7day
28day
90day
Flexural Toughness(Panels,
SFRS only)
ASTM C1550
Three (3) panels from the same shotcrete

batch for each 250m shotcrete
Dry Density (cored sample)
AS 1012.12 and AS
1012.14
Three (3) tests on three (3) specimens

from 7 or 28 day old shotcrete for each
250m3
Dry Density (cast sample)
AS 1012.8

250m3
AS 1012.21

3
250m
BS EN 14488.7
One test (meaning the average of tests on

3
3 specimens) for each 250m
Slump
AS 1012.3 and AS 1379
For every 50m3 produced after the

addition of plasticiser for each load
delivered.
Permeability
DIN1048
Minimum two (2) cores per one (1) weeks

production
Shrinkage Strain
AS1012.13
3
Three (3) specimens for each 500m of
shotcrete
Flexural Strength
ASTM C 1609
Three (3) specimens for each 500m3 of

shotcrete
Boiled Absorption
(permanent shotcrete only)
Fibre Content (SFRS only)
7.2
Compressive Strength Test
a) Compressive strength tests shall be carried out on prepared test cores of at least 75mm
diameter and with height: diameter ratio of 2:1 taken from shotcrete in the tunnels or
shafts, or from panels in accordance with AS 1012.14. For Permanent Works cores
shall only be taken from panels. The time of coring shall be not less than 20 hours after
placing. Cores required for 28 day strength tests and 90 day strength tests (when
required) shall be obtained at the same time as those for 1 and/or 7 day tests and
stored in the laboratory in accordance with AS 1012.14.
26 May 2010
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b) Depending on the compliance of test results with this Specification, circumstances of

application and importance of construction, the frequency may be reduced to every
250m3 or increased to every 50m3 as approved by the Construction Certifier. The
cores shall be cored through the whole thickness of the shotcrete and visually inspected
to verify that the shotcrete is dense and homogeneous without segregation of aggregate
and/or fibre or other visible imperfections.
c) Tests for 1 day strength shall be carried out at 24 hours 2 hours and for 7 day and 28
day and 90 day strength when required in accordance with AS 1012.14.
d) Instead of testing cores taken from shotcrete placed in the Temporary Works, indirect
test methods may be used to determine the 1 day strength. Results of indirect tests
shall be correlated to the 1 day in situ cylinder compressive strengths.
e) The strength of shotcrete measured by cores taken from the Temporary and Permanent
Works, shall be acceptable if the compressive strength results comply with the minimum
performance requirements. One test result shall consist of the mean of three core
strengths. Seven day results shall be used for indicative purposes only. The
compressive strength of cores in steel fibre reinforced or plain shotcrete shall be
deemed to be the in situ cylinder strength provided that the specified requirements are
met in terms of core diameter and height: diameter ratio.
7.3
Flexural Toughness Test
a) Tests to determine flexural toughness by the testing of round panels shall be carried out
in accordance with ASTM C1550.
b) Panels shall be clearly marked to identify the time, date and location of spraying. Panels
shall not be moved for 18 hours after spraying and shall be cured and protected.
c) Frequency of round panel testing shall be three (3) tests on panels (prepared from the
same shotcrete batch) for each 250 m3 of each Shotcrete Type S1 and P1 placed.
d) Shotcrete shall be acceptable if the results from round determinate panel toughness
testing are derived in accordance with ASTM C1550 and the results from at least 2 out
of 3 panels tested for each test exceed the minimum requirements of this Specification.
e) Samples for flexural toughness tests shall be taken from the same shotcrete as samples
for testing of steel fibre content (see Section 7.5). If four successive flexural toughness
tests demonstrate compliance with this Specification, and show a correlation with the
results of steel fibre content tests then, subject to approval of the Construction Certifier,
further testing for flexural toughness is not required.
7.4
Dry Density, Boiled Absorption and Voids Volume
a) Dry density, boiled absorption and voids volume shall be determined for shotcrete
sampled from the Temporary and Permanent Works. Material sampled for other
purposes may be used.
b) Shotcrete shall be acceptable if the average results for each test comply with the
specified requirements.
7.5
Fibre Content
a) Evaluation of fibre content shall be carried out on a 5 kg specimen of fresh SFRS

sampled immediately after spraying. The volume of the specimen shall be determined
in accordance with AS 1012. Fibre shall then be washed out of the sample and
collected, dried and weighed. The weight of fibre shall be related to the volume of the
sample in terms of kg/m.
b) The frequency of testing for fibre content shall be three (3) tests for each 250 m3 of
Shotcrete Type S1 and P1 applied.
26 May 2010
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c) The shotcrete shall be acceptable if the average result of the three tests exceeds the
specified minimum requirements and no individual result is less than the specified
minimum by more than 20%.
7.6
Slump
a) The slump of Shotcrete Types S1, S2, S3, P1, P2 and P3 shall be measured in
accordance with AS 1012.3 and AS 1379 after the addition of fibre (where required) and
plasticiser to the required dosages.
b) Shotcrete shall be acceptable if the slump is within the range nominated for the
approved shotcrete mix design.
7.7
Test of Steel Fibre
a) Tests on steel fibre shall be in accordance with ASTM A820-04 except that the cross
sectional area used to compute the tensile strength shall be calculated to four decimal
places, in units of square millimetres, and shall be:
i.
For drawn wire fibres, the area calculated from the actual diameter of the parent
source material or finished fibres
ii.
For cut sheet fibres, the area calculated from the actual thickness and width of the
parent source specimen, or if fibres are tested, the area of each individual fibre
calculated from the measured length and weight of the fibre, weighed to the nearest
0.0001 g, based on a density of 7,85 0kg/m3
iii. For melt-extraction fibres, the area calculated from the equivalent diameter of the
fibres, computed from measured average length and the weight of a known quantity
of fibres, based on a density 7,850 kg/m3
Repair of Shotcrete
8.1
General
a) Before repairing shotcrete, all test results as specified in Clause 7 shall be submitted for
approval unless where it is deemed by the Contractor the safety of the Works and
persons is endangered then shotcrete shall be repaired immediately Hold Point 3.
8.2
Core Hole Repair
a) The core holes/reamed holes shall be cleaned thoroughly with all loose material or
material that otherwise has the potential to break away, scaled back and refilled with dry
pack mortar
Remedial Works to Non-Conforming Shotcrete

9.1
General
a) If shotcrete is found to be cracked, delaminated, poorly bonded or poorly compacted, of

insufficient thickness, fails to meet specified strength or density requirements, or is
otherwise defective, the defective area shall be completely removed to the shotcrete
substrate, the surface re-prepared and the shotcrete replaced, provided it is structurally
safe to do so.
b) Should the results of any production tests not comply with the acceptance criteria set
out in the foregoing clauses of this Specification the results and test procedures shall
first be checked and confirmed Hold Point 4. The Contractor shall undertake additional
tests as necessary to determine the extent of the non-compliance and/or new mix
proportions or methods determined to avoid further such failures.
26 May 2010
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c) If the indicated non-compliance(s) may reduce unacceptably the stability or

serviceability of the Temporary and Permanent Works and are detrimental to the
effectiveness of the Temporary and Permanent Works, the Contractor shall either:
i.
Remove the defective shotcrete in strips or panels in such a way that the safety of
the Temporary and Permanent Works and persons is not endangered, and replace
with shotcrete that is acceptable, or;
ii.
Alternatively, if reviewed and recommended by the Construction Certifier, additional

shotcrete may be applied, or;
iii. Other repair methods recommended by the Construction Certifier

9.2
Compressive Strength Failures
a) If the strength requirements at 28 days are not met during the testing process, the
following actions are to be undertaken:
i.
Inform the Construction Certifier
ii.
Cores to be taken from the tunnel support
iii. Determine the non-conforming area

iv. Cores to then be tested and if they fail to meet the requirements of the Specification
then prepare proposals for strengthening of the area in cooperation with the
v.
The Contractor shall submit a remedial works proposal to the Construction Certifier
for review
vi. Repair the area by the method agreed with the Construction Certifier.
26 May 2010
Page 33

Appendix A
Verification Records
Appendix B
Response to Comments
EXTERNAL (IV,CNI,BC): WORK VERIFICATION RECORD - DESIGN REVIEW COMMENT, RESPONSE AND INCORPORATION RECORD
Date:
26/05/2010
Rating Impact
1 = high impact
Post AFC - DCN
GL - Supplementary Specification - Tunnel
2 = medium impact
WVR: GLTSP102VL16B
Shotcrete Lining
3 = Low impact
Close out status - IV & TJH use only

Spec re-issued as version -0002 by TJH/PB apparently including response to IV/CNI comments on version -0001 but
without updated Designer response in WVR . All comments Closed apart from Comment 11. AWC 13 April 2010
DCN Stage 2 Consolidated Comments- IV, BCS & CNI Issued to TJH 24.03.2010
24-5-10 Gate 54
VL16B 1-01
No.
Name
Discipline
Area-Organisation
Document
Revision
Robert Burke
Geo/Tunnelling
IV
DCN 00047
BC-PBA-GLTSP102SPC
0001
Robert Burke
Geo/Tunnelling
IV
DCN 00047
BC-PBA-GLTSP102-
0001
No.
Name
Discipline
Area-Organisation
Document
Revision
Reference
Reviewer Comment- IV- DCN
BC-PBA-GLTSP102-SPC-0001
Section 5.3
Please detail who is to determine what remedial measures if any are required prior to
placement of shotcrete.
Section 5.3.1
It is unclear what is the maximum aggregate size for the smoothing layer as maximum
aggregate sizes detailed in ii and xi are different. Please clarify.
Reference
Rating
Impact
IV Status
TJH Comment
Designer response
The waterproofing supervisor has been added and reference
made to his responsibilities in accordance with specification
BC-PBA-GLTSP107-SPC-0001
Noted. Iii) deleted (Not used) and xi applies.
Response
agreement
Incorporated
CLOSED
CLOSED
No.
Name
Andrew Axton
Discipline
Area-Organisation
Document
Revision
CNI
DCN 00047
BC-PBA-GLTSP102SPC
0001
Reference
Section 1.2 Definition of Terms
Incorporated
Reviewer Comment- BCS- DCN
Rating
Impact
IV Status
TJH Comment
Designer response
Response
agreement
Incorporation status
Reviewer Comment- CNI- DCN
Rating
Impact
IV Status
TJH Comment
Designer response
Response
agreement
No Comments
N/A
Words revised as follows
With reference to the definition for silica fume concrete, is not known what
is meant by the statement 'care should be taken in the choice of
cementitious material to ensure that sufficient lime is available for reaction
with silica fume'. It is not evident why the requirements for lime quantities are
not defined within this specification. Please address this issue.
"Concrete manufactured in the concrete mixer by combining

cement complying with AS 3972 with silica fume. The
Contractor shall ensure that (Care should be taken in the
choice of cementitious materials to ensure that sufficient lime is
available for reaction with the silica fume, particularly when
sulphate resistant cement or pulverised fuel-ash is used).
Incorporated
CLOSED
The % is detailed in AS 3972. we do not want to repeat this.
10
11
Andrew Axton
Andrew Axton
Andrew Axton
Andrew Axton
Andrew Axton
Andrew Axton
Andrew Axton
CNI
CNI
CNI
CNI
CNI
CNI
CNI
DCN 00047
BC-PBA-GLTSP102SPC
0001
DCN 00047
BC-PBA-GLTSP102SPC
0001
DCN 00047
BC-PBA-GLTSP102SPC
0001
DCN 00047
BC-PBA-GLTSP102SPC
0001
DCN 00047
BC-PBA-GLTSP102SPC
0001
DCN 00047
BC-PBA-GLTSP102SPC
0001
DCN 00047
BC-PBA-GLTSP102SPC
0001
It is noted that the text implies that dosages outside the manufactures
recommended dosage could be used. It is also noted that 10% dosage of
accelerator could have detrimental effects on the long term strength gain of
the shotcrete. Please address this issue.
Specification Section 3.10, Table It is noted that reference has been made to AS5100.5 with respect to
10
exposure classifications and maximum acid-soluble chloride ion contents.
Given that AS5100.5 only applies to concrete works, and noting that installed
shotcrete is different to cast-in-situ concrete, it is not evident if the durability
assessment, as required by Section 6.6.2 of Annexure 1 Part 1 of the
Performance Specification, has taken into account the performance criteria
of shotcrete to meet the durability requirements and the required Design Life
of the underground structure in the environment in which it is situated.
Please address this issue.
Noted. Words added to state that dosage shall not exceed

manufacturers recommendations
Specification Section 4.2, Table

11
It is noted that the use of fly ash is not mandated in the shotcrete mix
requirements. It appears that specifications, whilst specifying performance
criteria, also need to take into consideration (and specify) durability criteria.
It is not evident that the fly ash content specified is consistent with the
durability report. Please address this issue.
It is noted a W/C ratio of 0.45 has been specified for permanent shotcrete. It
is not evident that the W/C ratio specified is consistent with the durability
report. Please address this issue.
Ths comment is the wrong way around. The durability report

has now assessed both initial shotcrete and permanent
shotcrete for durability based on the shotcrete specification
and confirmed the design life is 100 years
Ths comment is the wrong way around. The druability report
CLOSED
It is noted that the text states that target slumps shall be determined by trial
mixes, but then goes on to specify the target slump. Please address this
discrepancy.
determined has been replaced by confirmed. Trails shall be

conducted in accordance with this clause to "confirm" the
slumps fall within the range specified in this clause.
CLOSED
It is not evident how it is intended to demonstrate that permanent shotcrete

having an allowable shrinkage strain of 850 microstrain (as prescribed in the
Shotcrete Specification) complies with the durability requirements, noting
that reinforcement may be used in some areas of the permanent shotcrete
lining/s. Please address this issue.
Ths comment is the wrong way around. The durability report

Report Section 3.8.2(e)

11
Report Section 4.4(b)

13
Report Section 6.3(f)
It is not evident with reference to the use of a drop pipe, what is meant by
'overly segregated', how this will be determined, and who will determine this.
Please address this issue.
Incorporated
CLOSED
Noted.
The issue of shotcrete durability is now addressed in Durability
Report which covers shotcrete. Shotcrete is concrete with the
method of placement being the only difference. A reference to
teh durabilty report has been added to the specififcation and
the following text added to section 1.1
Incorporated
CLOSED
The durability of shotcrete manufactured with this shotcrete

specification has been assessed in BC-AGDTR100-RPT0001.
Comment added 07/04/10. The

reference made is to the fact that an
overly segregated concrete will not
be able to be sprayed or placed.
The WMS on site requires the
concrete to be both physically and
visually assessed. Over segregated
will be a visual assessment by TJH.
It is not possible to specify every minute detail of construction.

It should be noted that poor gap graded non homogenous
concrete will not pump or can be sprayed. These construction
actions are self policing.
N/A
CLOSED
N/A
Incorporated
N/A
CLOSED
N/A
OPEN
19-5-10 CLOSED
VL16B 1-02
No.
Name
Discipline
Area-Organisation
Document
Revision
Reference
Reviewer Comment
12
Andrew Axton
CNI
Report-General
It is not evident from the report whether the comments from the previous issue of this
DCN have been addressed. These comments were issued under TRIM ref: 10/18239
12 March 2010 (letter reference 10/20116). Please address this issue
13
Andrew Axton
CNI
Report Section 5.3.1(b)
It is noted that item (iii) and item (xi) contradict each other with respect to aggregate
size. Please address this discrepancy.
IV Status
*
Y
N
M
N/A
Means
Means
Means
Means
Means
Response acceptable - will be closed when completed

Complies with Project requirements
Does not comply with Project requirements
Minor non compliance with Project Requirements
Not Applicable to this design lot
Transmittal
Stage
Doc Number
Revision
Area
Element Title
Review Comment External-IV-CNI
Rating
Impact
IV Status
TJH Comment
Designer response
Comment added 07/04/10. It would

appear from the comment sheet that
the IV considers the items have been
included and closed with the
exception of Item 11.
Comment added 07/04/10. Comment agreed. Item iii has

been deleted to remove the discrepancy
Response
agreement
19-5-10 CLOSEDN/A
Conditional of
incorporation of
designer response
19-5-10 CLOSEDConditional of
incorporation of
N/A

Specification - Tunnel Shotcrete Lining

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Specification - Tunnel Shotcrete Lining

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Cv

Thiess John Holland

Thiess John Holland

Parsons Brinckerhoff Arup Joint Venture ABN 88 642 968 608

This report takes into account the

Airport Link | Northern Busway | EWAG

GL - Supplementary Specification - Tunnel - Shotcrete Lining

AFC Issue 25/02/09

Issued for Review, DCN: 00047, Refer to Table 2

Issued for External Review, DCN: 00047, Refer to Table 2

Issued for IFA / AFC, DCN: 00047, Refer to Table 2

Issue Document Verification with Document

Parsons Brinckerhoff Arup Joint Venture

Thiess John Holland Joint Venture

Airport Link | Northern Busway | EWAG

Standards and Related Specifications

Discrepancy Between Drawings and Specification

Changes to previous revisions

Records Maintained by the Contractor

Quality System Requirements

Hold Points, Witness Points and Milestones

Work Method Statements

QDMR Registered Suppliers and Products

Supplementary Cementitious Materials

Alkali-Aggregate Reaction (AAR)

Soluble Salts (permanent shotcrete only)

Construction Method Statements

Acceptance Testing and Field Trials

Sprayed Concrete Trials

Surface Preparation for Shotcrete Application

Preparation of Rock Surfaces

Preparation of Shotcrete / Concrete Surfaces

Preparation for Installation of Waterproof Membrane

Application of Shotcrete and Curing

Thiess John Holland Joint Venture

Airport Link | Northern Busway | EWAG

Production and Transport

Thickness and Profile Control

Compressive Strength Test

Flexural Toughness Test

Dry Density, Boiled Absorption and Voids Volume

Test of Steel Fibre

Core Hole Repair

Remedial Works to Non-Conforming Shotcrete

Compressive Strength Failures

Parsons Brinckerhoff Arup Joint Venture

Thiess John Holland Joint Venture

Airport Link | Northern Busway | EWAG

This specification supersedes Shotcrete Lining (reference AGTSP100-0002).

steel or synthetic fibre reinforced shotcrete (SFRS),

steel mesh reinforced shotcrete

and plain or unreinforced shotcrete (URS)

plain shotcrete with polypropylene fibres to provide fire protection

aggregates for use in permanent shotcrete requiring fire resistance

URS applied as a smoothing layer prior to installation of the tunnel waterproofing

Parsons Brinckerhoff Arup Joint Venture

Thiess John Holland Joint Venture

Airport Link | Northern Busway | EWAG

Relative Strength for

Materials added to base concrete such as accelerators and hydration

An active hydraulic binder formed by grinding clinker and conforming to AS

The value of the standard cylinder strength at 28 days below which 5% of

Sprayed concrete applied as a thin layer protecting, priming or finishing the

The notional strength of shotcrete at a single location, considered as the