SHOTCRETE FAQ

An experienced shotcrete placement contractor can very often double the daily production of the form-and-pour process. Shotcrete production, among several other factors, is influenced by a crew’s ability to physically access the wall. Production goals should be discussed during a pre-construction meeting. A “shoot” plan should address pipe sleeves, wall embeds, and structural columns which may affect a contractor’s ability to move within the site. 

We’re glad you’re interested to learn more about shotcrete. 

1. Call or email CCP to schedule a free, one hour in-person or online presentation on shotcrete that’s been specifically developed for engineers, General Contractors and Project Owners. Topics include shotcrete considerations, project preparedness, expectations, specifying of documents and shotcrete inspection.
2. See our Shotcrete Specifications page for shotcrete articles, position papers and industry-accepted shotcrete specifications.
3. Call CCP to discuss your upcoming project(s) right now.

CCP’s typical scope of work is to pump, shoot, finish and cure concrete via the shotcrete process. Each day a new section is complete. No forms to strip. No waiting in between pours. And the process can be performed each and every day.

One of the biggest advantages shotcrete offers is its ability to incorporate into most construction scenarios. Whether you are in the initial stages of project design or already under construction, shotcrete’s flexibility allows for quick insertion and execution. In fact, CCP services are often obtained as a change order to replace cast-in-place concrete construction. There are, however, several topics that should be considered prior to shotcreting. Call CCP for an introduction to your project. We’ll guide you through our project checklist to help ensure the shotcrete scope is a complete success.

CCP is headquartered in Austin, Texas. CCP services Texas and surrounding States. Project scope/scale and resource availability help determine serviceability. 

How much is a day worth in dollars to your overall project? Shotcrete thrives in today’s construction industry for its ability to accelerate a project’s schedule. Unlike cast-in-place, there are no forms to strip. This means no downtime between shotcrete days. A Contractor’s focus typicaly shifts from shotcrete production goals to making sure trades preparing the work area are able to keep up. Other time saving shotcrete advantages include:

• No concrete footings required for wall supports.
• Reduced (or the elimination of) crane time for form setting or concrete pouring.
• Faster concrete set-up reduces labor costs.
• Reduction of forming materials by up to 100%

Shotcrete is a method of placing concrete. It has many advantages when compared to the form-and-pour process. The term, “Waste”, and its association with shotcrete should be analyzed carefully. Shotcrete “waste” is generally comprised of rebound and excess cutting/shaping of the plastic concrete. So long as shotcrete “waste” is within industry-accepted parameters, it should be considered a PART of the shotcrete process, not a detriment to it. 

Shotcrete “waste” can sometimes be confused with other factors during the course of work. Is the wall true to thickness? A 12″ specified wall that is 13″ thick in the field results in over an 8% increase in concrete consumption. Finally, if a ready mix truck leaves the site with an extra 1-2 yards in the drum, be sure to not consider that waste. That’s simply an over-order of concrete.

A project group should be in alignment from the beginning on shotcrete expectations. This topic is no exception.

CCP is your qualified shotcrete contractor. Shotcrete is exclusively what we do. Our shotcrete crews have been working TOGETHER in the field and in the office since 2009. We understand our role as shotcrete educators, contractors and true partners. We pride ourselves on our customer service – quick response times, direct communication with shotcrete estimators and project managers, and commencing work on the day we’ve committed to. Our clients do not wait on us. 

CCP’s continuing education efforts are unmatched. American Shotcrete Association (ASA) participation as a sustaining corporate member, expert consultant training and a company culture that promotes continual improvement are just a few of the efforts CCP has in place. 

Our reputation means everything. We’d be happy to put you in touch with our past clients. Every project comes with a positive reference, and we plan to keep it that way.

CCP has worked with many of the State’s most highly regarded general contractors. We typically either contract directly with the General Contractor, or as a second tier subcontractor.

American Concrete Institute (ACI) Shotcrete Specifications and supporting resources may be accessed from our website. CCP stands by to assist in the specifying of your project’s shotcrete scope of work.

Yes. CCP has American Concrete Institute (ACI) certified shotcrete nozzlemen. CCP also has a nozzleman in-training program ensuring Contractors in Texas and surrounding States will have experienced shotcrete nozzlemen in the decades to come. But finding a certified nozzleman shouldn’t be your end-all goal. A nozzleman alone cannot produce a successful shotcrete project. A qualified shotcrete team consists of approximately 8 field positions, each as important as the next, and all requiring training and experience. 

Shotcrete is a method of placing concrete, not a type of concrete or any particular product. Over the years, CCP has spent countless resources in developing advanced concrete mixes specifically for shotcrete. Below are a few, very basic differences between a cast-in-place (form-and-pour) concrete mix and a concrete mix for intended for shotcrete. 

Slump. A 2″ to 3″ slump is typical for a shotcrete mix, compared to a 4″-5″ slump for a cast in place mix. 

Aggregate Size. The large aggregate size used for shotcrete is typically 1/2″ and smaller. Form-and-pour concrete’s large aggregate is regularly 1″ to 1.5″. The size difference is due to the diameter of the concrete pumping equipment; usually consisting of 2″ hose and steel pipes, and a 2″ diameter shotcrete nozzle.

W/CM. A concrete mix used for shotcrete typically has a lower water-to-cementitious material ratio of 0.35 to 0.45.

There are several advantages to having a reputable ready mix vendor service a high profile shotcrete project.  These advantages can be split into two categories – improved concrete material quality and an alignment of parties’ interests.

Concrete Material Quality
Aggregate Gradation. A ready mix vendor more-reliably produces a mix with a well-graded aggregate distribution. A volumetric mixer has only several compartments, including one for a large aggregate and one for sand (small agregate). Whereas ready mix material has time to thoroughly mix all concrete components, a volumentric truck may result in a Gap Graded aggregate curve.

Chemicles. The adding of chemicals on site during the course of work can improve shotcrete productivity. Although volumetric truck advancements are impressive, a ready mix truck always allows for the proper mixing of required chemicals.
Consistency. A ready mix vendor’s concrete mix is produced at a centralized plant, more often resulting in true consistency from truck to truck.

Party Interests
CCP is a shotcrete contractor. Contractors and Owners rely on us for high workmanship and high productivity. We do not produce concrete. And for good reason. A company that provides shotcrete services AND sells concrete material are incentivized to sell you more concrete. Conversely, CCP relies on quality concrete from reputable ready mix vendors. It’s our incentive to NOT produce excessive amounts of shotcrete “waste” or back-charge clients for concrete. 

Shotcrete doesn’t simply produce a gun / nozzle finish. Many are surprised to learn that shotcrete can be finished to almost any class, type and tolerance. A sponge float, broom, Class A steel trowel and architectural finishes are all attainable. Concrete finishes should be incorporated into specification, and performed and approved as part of a the mock-up prior to the start of a project.

A concrete placing process where concrete mixtures are conveyed through a hose then pneumatically projected at high velocity onto a surface to achieve high quality in-place compaction. It produces high quality dense concrete, with a low w/cm ratio, low permeability, and a high cementitious material content.

Remember, shotcrete is a process, not a type of concrete.

Whether CCP is specified from the onset or you’re looking to accelerate your schedule during construction CCP has the ability to begin a shotcrete project at almost any stage. We understand our services sometimes are needed in emergency situations. We’re standing by to accommodate your service request.

The American Shotcrete Association (ASA) has an impressive, ever-growing list of shotcrete questions and answers. CCP is a sustaining corporate member of the American Shotcrete Association.

https://shotcrete.org/products-services-information/technical-questions-archive/