Shotcreting Automation

Shotcrete is used both in mining and tunnelling for supporting rock. Both dry and wet processes are used for shotcreting, and each produces good quality concrete. Thick shotcrete layers function as a concrete arch supporting loose rock. Thin layers prevent relative movements between the blocks of rock due to the fine concrete in the cracks and joints. No progressive fallouts occur since key blocks are kept in place. Rockbolts are often used together with shotcrete in order to create an arch around the tunnel making the rock to support itself. Shotcrete is sprayed either manually or by means of mechanized equipment. The aim is to spray required the layer thickness in one pass and with a minimum amount of rebound. Sprayed layers should also be as even as possible. The tip of the nozzle should be moved in circular movements. The shotcrete should be sprayed at a right angle to the rock surface; the optimum distance from the nozzle to the application surface must be found by experiment. In a mine shotcreting forms a materials handling system which includes batching, transporting and the actual shotcreting. The equipment used vary depending on the spraying method, mining conditions and the location of the mine. Shotcreting is performed with a purpose-designed unit in most cases where operation is mechanized. The shotcreting unit consists of a spraying machine with a hose and a nozzle, an additive system, a manipulator and a mobile carrier with all the necessary controls and accessories. The key element of the unit is the shotcreting manipulator which holds and guides the nozzle as required. The manipulators currently in use are hydraulically operated, and their remote controlled booms are also often called robots. These manipulators have enabled users to increase their output capacities, to remove the operator away from unsafe areas and from the influence of dust and rebound. Furthermore, they improve the shotcrete quality and reduce shotcreting costs.