Section 566.

SHOTCRETE
Delete the text of this Section and substitute the following: Description 566.01 This work consists of constructing one or more courses of fiber reinforced structural shotcrete onto a prepared surface and colored sculpted shotcrete to match the adjacent rock. This work also includes installing weep holes and fiber reinforced shotcrete for guardwall underpinning. 566.02 Definitions. (a) Structural Shotcrete. Structural shotcrete consists of one or more layers of shotcrete conveyed through a hose and pneumatically projected and compacted at a high velocity against a prepared surface. (b) Sculpted Shotcrete. Sculpted shotcrete consists of structural shotcrete manually sculpted and finished as a shotcrete facing. The sculpted shotcrete is intended to conceal the presence of structural shotcrete by matching the native rock characteristics unique to Glacier National Park. (c) Reinforced Shotcrete (guardwall underpinning). Reinforced shotcrete for guardwall underpinning consists of fiber reinforced shotcrete placed against a prepared surface beneath existing guardwall sections. Material 566.03 Conform to the following Subsections: Air-entraining admixture (wet mix only) Chemical admixtures (wet mix only) Concrete coloring agents Curing material Hydraulic cement Mortar 712.05(b) Penetrating stain Pozzolans Reinforcing fibers Reinforcing steel Shotcrete aggregate Water 725.01(a) 711.02 711.03 711.05 711.01(d) 701.01(a) 708.05 725.04 725.29 709.01 703.18

Shotcrete aggregate grading is designated as shown in Table 703.15, grading B.

Construction Requirements 566.04 General. Furnish and construct structural and sculpted shotcrete according to the requirements of ACI 506R Guide to Shotcrete, ACI 506.1 State of the Art Report on Fiber Reinforced Shotcrete, and the latest version of ACI 506.2 "Specifications for Materials, Proportioning and Application of Shotcrete". Submit temporary roadway protection and monitoring plans at least 14 days prior to performing work in accordance with Section 651. 566.05 Qualifications. Submit in writing to the CO 30 days before starting shotcrete work the qualifications of each foremen, nozzlemen, and finishers assigned to the project. Include the name of the past project, location, brief description of shotcrete work performed, a current contact (name, address, and phone number) for the owner of which the work was performed and the following: (a) Foreman. Provide foremen experienced in shotcrete construction on at least five projects of similar character and complexity. (b) Structural shotcrete nozzleman (SSN). Provide personnel who have successfully completed at least three projects within the past five years as a shotcrete nozzleman. Submit written proof of certification according to ACI 506.3R Guide to Certification of Shotcrete Nozzleman or demonstrate satisfactory completion of preconstruction test panels according to Subsection 566.08. (a) Finished treatment nozzleman (FTN). Provide personnel who meet the same qualifications as those of SSN, but with at least ten years of experience. Submit photographs of past work on shotcrete projects. (b) Finishers. Provide personnel who have successfully completed at least three projects in which they have been primarily responsible for producing the sculpted shotcrete finishes intended to match colors and textures of adjacent surroundings. 566.06 Composition (Shotcrete Mix Design) and Submittals. Design and produce shotcrete mixtures that conform to Table 566-1. Verify mix design with trial mixes prepared from the same source proposed for use. Submit five copies of the following for acceptance at least 36 days before placing shotcrete: (a) Proposed shotcrete mix design with mix proportions. Include the dosage and type of any admixture with proposed mix design; (b) Shotcrete materials certifications, including cementitious materials, aggregates; admixtures and curing compounds;

(c) Appropriate test results of shotcrete materials to meet the requirements of table 566-1. If requested by the CO, include representative samples of shotcrete materials; (d) Reinforcing fiber manufacturers product literature and sample of fibers. Include method of incorporating fibers into shotcrete; (e) Accelerator compatibility certifications if accelerator is used; (f) Proposed methods for applying shotcrete, including methods for controlling and maintaining shotcrete thickness and methods for providing curing and protection of in-place shotcrete during hot and cold weather; (g) Coloring agents for obtaining the integral color of the sculpted shotcrete and any acrylic latex paints or acid-based stains; (h) Description of equipment for mixing and applying shotcrete. Include the manufacturers instructions, recommendations, literature, performance, and test data. In addition to meeting equipment requirements in ACI 506, provide the following: (1) Water supply system. For dry mix, provide a job site water storage tank. Provide a positive displacement pump with a regulating valve that is accurately controlled to provide water at the required pressure and volume. (2) Mixing. Use equipment capable of handling and applying shotcrete containing the specified maximum size aggregate and admixtures. Provide an air hose and blowpipe to clear dust and rebound during shotcrete application. (i) Other information necessary to verify compliance with ACI 506.2. Table 566-1 Composition of Shotcrete
Type of Shotcrete Process Wet Dry Wet (AE) Minimum Cement Content (pounds per cubic yard) 137.50 137.50 137.50 Maximum W/C Ratio 0.45 0.45 0.45 Maximum Chloride Ion Content % 0.10 (1) 0.10 (1) 0.10 (1) 0.10 (1) Air Content Range % NA NA 5 min. 5 min. Minimum 3Day Strength (pounds per square inch) 2000 2000 2000 2000 Minimum 28Day Strength (pounds per square inch) 4000 4000 4000 4000

Dry (AE) 137.50 0.45 (1) As determined by AASHTO T260

Allow 14 days for acceptance or rejection of submittals. Do not begin work until submittals have been approved. Resubmit any proposals to change or modify the approved submittals for approval before using. The CO will accept or reject the new proposals within 14 days of receipt of revised submittals. No contract time adjustment will be allowed due to incomplete submittals.

566.07 Hydration Stabilizing Admixtures. When hydration-stabilizing admixtures are used to extend the allowable delivery time for shotcrete, include the admixtures in the shotcrete mix design. Base dosage on the time needed to delay the initial set of the shotcrete for delivery and discharge on the job. Include the design discharge time limit in the dosage submittal. The maximum allowable design discharge time is 3.5 hours. Use an approved and compatible hydration activator at the discharge site to ensure proper placement and testing. Determine dosage required to stabilize shotcrete using job site material and field trial mixtures. The extended-set admixture shall control the hydration of all cement minerals and gypsum. When requested, the admixture manufacturer shall provide the service of a qualified person to assist in establishing the proper dose of extended-set admixture and to make dosage adjustments required to meet changing job site conditions. 566.08 Preconstruction Testing. Conduct preconstruction shotcrete field trials before starting shotcrete production. Notify the CO 7 days in advance of preparing preconstruction test panels. (a) Field trials. Construct test panels from 30-inch by 30-inch by 4-inch minimum wood forms. Slope the sides of test panel forms outward at 45 degrees on all sides to release rebound. Construct panels for each shooting position to be encountered in the structure; e.g. vertical and overhead. Have each proposed nozzleman produce shotcrete panels on two wood forms, each at differing positions. Cure the test panels according to AASHTO T 23 except do not immerse the panels. (b) Coring. Take nine 3-inch diameter cores from each test panel according to AASHTO T 24. Trim the ends of the cores according to AASHTO T 24 to make cores at least 3 inches long. Do not trim the ends of cores to be tested for boiled absorption test. (c) Compressive strength testing. Soak the cores in water for 40 hours immediately before testing. Test three cores from each test panel four days after the field trial and test three cores 28 days after the field trial. Perform tests according to AASHTO T 23. (d) Boiled absorption. Test three cores from each test panel seven days after the field trial for boiled absorption. Perform test according to ASTM C642. (e) Sculpted shotcrete. Create sculptured test panels in the field within the vicinity of representative rock cuts. Size the panels to sufficiently reflect an accurate rendering of the proposed features. The sculpted concrete facing test panels will be evaluated according to Subsection 106.02 with respect to the aesthetic requirements of Subsection 566.12. Additional test panels may be required until the proposed sculpted shotcrete facing is approved by the CO.

(f) Mix design acceptance. Submit the test data and a visual description of each core to the CO. Include details concerning presence of voids, sand pockets, lamination, and other inadequacies. Acceptance of the nozzlemen and mix design will be based on preconstruction field trials and test results. The visual quality of the cores shall not be lower than grade 2 according to shotcrete grading requirements of ACI 506.2. Submit field quality control test reports within 2 working days of performing the tests. Include the following information in the reports: Sample identification including mix design and test panel number and orientation; Date and time of sample preparation including curing conditions and sample dimensions; Date, time, and type of test; Complete test results including load and deformation data during testing, sketch of sample before and after testing, and any unusual occurrences observed; Name and signature of person performing the test; Location of steel reinforcement covered by shotcrete; and Name of nozzleman.

566.09 Anchors. Install reinforcing steel in drilled and grout-filled holes as shown in the plans before applying shotcrete. Install reinforcing steel to maintain a minimum spacing of 5 feet on center both vertically and horizontally. 566.10 Weep Holes. Construct weep holes 3 feet in length, installed through the structural shotcrete to drain water from behind the facing. Extend the weep drains through the structural shotcrete facing to intercept fractures in the rock. If the horizontal width of the shotcrete area is greater than 10 feet, install additional weep drains on 5-feet spacing. Hole linings are not required. Prevent shotcrete intrusion from entering or clogging the weep drains. Provide additional drainage measures, as needed, in addition to the described pattern or adjust the spacing of the weep drains as directed by the CO to allow proper drainage of any observed springs or seeps exposed as surface preparation proceeds. Apply finishes to disguise the weep drains so they appear as natural seeps exiting through rock fractures in the sculpted shotcrete facing. 566.11 Shotcrete Construction. following: Apply shotcrete according to ACI 506R and the

(a) Surface preparation. Moisten all surfaces.

(1) Clean existing surfaces of loose materials and other foreign matter. Divert water flow and remove standing water within the application area. Install approved depth gauges to indicate the thickness of the shotcrete layers. Install depth gauges on 6-foot centers longitudinally and transversely with no less than two gauges per increment of surface area to receive the shotcrete. (2) Sandblast the structural shotcrete surface as need to remove any residue or curing compound that may prevent effective bonding before applying the sculpted shotcrete facing. (b) Temperature and Weather Conditions. Maintain the temperature of the shotcrete mix between 50 F and 90 F. Place shotcrete when the surface and ambient temperature is at least 40 F and rising. Do not perform shotcrete operations during high winds and heavy rains. Schedule the work when favorable ambient conditions prevail or take mitigating measures such as installing sunscreens, wind breaks or heating tents to adequately protect the work. (c) Shotcrete application. Use the same nozzlemen that created acceptable test panels. (1) Apply shotcrete within 45 minutes of adding cement to the mixture. (2) Limit the layer thickness of each shotcrete application to 2 inches. Thicker applications may be approved if the Contractor can demonstrate that no sloughing or sagging is occurring. If additional thickness is required, broom or scarify the applied surface and allow the layer to harden. Dampen the surface before applying an additional layer. (3) Apply the structural shotcrete from the lower part of the area upwards to prevent accumulation of rebound. Maintain the thickness of the shotcrete application to avoid slumping. Orient nozzle approximately perpendicular to the working face and at a distance such that rebound is minimized and compaction is maximized. Use a blowpipe to remove slumped shotcrete from the rock surface or any accumulated rebound immediately ahead of the nozzle. Do not incorporate rebound or slumped shotcrete into final shotcrete. (4) Apply the layer of structural shotcrete in a manner that retains the underlying shape of the natural rock in order to leave a more naturally shaped base for the final application of sculpted shotcrete. Other than thickness control and to properly encapsulate the anchors, there should be no attempt to intentionally create a surface that is flat, plumb or straight. (5) Prepare construction joints to a thin edge over a distance of at least 12 inches. Wet the joint surface before placing additional shotcrete on the joint. Do not use square construction joints.

(6) Repair any shotcrete surface defects as soon as possible after placement. Remove and replace shotcrete that exhibits segregation, honeycombing, lamination, voids, or sand pockets. (d) Production sampling. Prepare at least one test panel per shift or as directed by the CO. Construct production test panel from 18-inch by 18-inch by 4-inch wood form. Take core samples from the production test panel in accordance with AASHTO T 24. (e) Reinforced Shotcrete for Guardwall Underpinning. Excavate beneath the stone masonry, at locations shown on the plans, using hand tools. Remove all loose material and excavate a flat level bench and prepare surfaces for shotcreting. Place the reinforced, welded wire shotcrete to within 8 inches of the existing guardwall face. Trim shotcrete and create a vertical planner surface. Place stone masonry against the shotcrete in accordance with Subsection 620.06. 566.12 Sculpted Shotcrete Finishing. Construct sculpted shotcrete facing at designated areas to mimic the adjacent native rock slope characteristics. Do not include reinforcing fibers in sculpted concrete facing. Provide the following features: Coverage of structural shotcrete treatment area with seamless transitions from natural to simulated features Artificial fractures that match the jointing and fracturing of the adjacent native rock; Non-discernable patterns; Naturally appearing weep holes; Naturally appearing color schemes; Naturally appearing shadow patterns; Visible feature relief; and Visible texture and color blending to match as much as practicable the adjacent native rock characteristics 566.13 Curing Shotcrete. Begin curing immediately after the free surface water has evaporated and the finishing is complete. If the surface of the shotcrete begins to dry before curing compound can be implemented, keep shotcrete surface moist using a fog spray without damaging the surface. Apply liquid membrane curing compound according to the manufacturers recommendations. Cure all structural shotcrete layers in which the sculpted shotcrete facing will be applied more than four hours after completion of the structural shotcrete. If curing compounds are used on intermediate layers, they must be sandblasted off. Use curing compounds that will not form a barrier to coloring agents on the final layer of sculpted shotcrete.

Keep shotcrete surfaces from freezing for at least 7 calendar days after application. Maintain shotcrete at a temperature above 40 F until shotcrete has achieved a minimum compressive strength of 750 pounds per square inch. 566.14 Production Report. Prepare and submit a written report within 24 hours of shotcrete production and application for each shift. Include the following information in the report: (a) Quantity and location of shotcrete applied including sketches of areas where shotcrete was placed. (b) Observations of success or problems of equipment operation, application, final product condition, and any other relevant issues during production and application; (c) Batch number(s) if applicable. (d) Name of nozzleman; and (e) Name and signature of person performing the observation. 566.15 Acceptance. See Table 566-2 for sampling and testing requirements and the acceptance quality characteristic category. Material for shotcrete will be evaluated under Subsections 106.02 and 106.03. Furnish a production certification for the hydraulic cement. The shotcrete placement system will be evaluated under Subsections 106.02 and 106.04. Shotcrete air content and unit mass will be evaluated under Subsections 106.02 and 106.04. Compressive strength will be evaluated under Subsection 106.04. See Table 566-1 for specification limits. Sculptured concrete facing will be evaluated under Subsection 106.02 Measurement 566.16 Measure the Section 566 items listed in the bid schedule according to Subsection 109.02 and the following as applicable. Measure structural shotcrete by the square yard to the nearest 0.1 square yard of finished shotcrete surface area. Measure sculpted shotcrete by the square yard to the nearest 0.1 square yard of finished sculpted shotcrete surface area. For purposes of differentiating sculpted shotcrete and structural shotcrete, assume an average sculpted shotcrete thickness of 5 inches. Payment

566.17 The accepted quantities will be paid at the contract price per unit of measurement for the Section 566 pay items listed in the bid schedule. Payment will be full compensation for the work prescribed in this Section. See Subsection 109.05.