Shotcrete machine for pools
2020-04-01 10:43:28
Shotcrete machine for pools
Dry and wet shotcrete machine are widely used in the construction of swimming pools.
Every swimming pool or waterpark design is different and the types of structures used for each application need to be customized to meet the individual needs of each facility.
Properly designed and constructed, concrete pools will last many decades with very little upkeep expense related to the structure.
Each time we design an aquatic center, we customize the various concrete formulas to meet the strength and water-tightness characteristics necessary for properly constructed swimming pools. While designing the concrete formulas, our engineers take into consideration the aggregate materials available in the geographic area of the aquatic center and the type of concrete application that best fits the project, shotcrete, gunite, and cast-in-place concrete.
Our typical design utilizes cast-in-place concrete for pool floors, in order to get a good uniform surface for pool users to walk on, with shotcrete concrete or gunite concrete for the pool walls in order to get very strong and watertight construction with few pool joints.
Both shotcrete and gunite are what is referred to as “free form” applications of concrete. Free form, by its very nature, enables concrete to be used to create very strong and watertight structures following any type of geometry. The concrete can be applied horizontally or vertically and can even be shot upward to adhere and form to the underside of a ceiling.
With shotcrete, the entire concrete mixture is combined at the concrete plant, including the water in the mixture, before being transported to the jobsite in concrete trucks. This is the same procedure that is used for cast-in-place concrete with the exception of the lower water content in the shotcrete mixture.
Once the concrete arrives at the jobsite, it is poured into the wet shotcrete machine and sprayed under pressure into place in layers through a back-and-forth motion of the nozzle. The shotcrete application continues until the designed wall thickness is achieved.
The result of using shotcrete for swimming pool walls is a much stronger wall with fewer joints between wall sections, than with a cast-in-place wall.
One thing that must be considered when using shotcrete in pools is the experience factor. It is critical with any construction that the contractor building the pool be highly experience with the methods of construction being used. With shotcrete, the person operating the shotcrete hose and nozzle is the absolute key to getting a great result from the concrete.
When done properly, shotcrete results in a much stronger and watertight installation than with cast-in-place.
Pros
When properly designed and constructed, shotcrete (or gunite, which will be discussed next) will result in the strongest and most watertight concrete pools possible.
Because of the lower volume of water used in the concrete mixture, there is less volume change from water hydration, which results in much fewer joints in the pool. Remember the rule of thumb for good pool design and construction is to “minimize the number of pool joints between concrete sections in the pool.”
Higher compressive strengths than cast-in-place concrete. Typical compressive strengths of shotcrete are in the range of 6,000 to 7,500 psi.
“Free form” application makes it possible to build very strong and watertight structures of any shape.
Cons
Like all concrete installation, the contractor must be experienced and skilled in the particular technique of installation. There are fewer people skilled in the use of shotcrete than that of cast-in-place concrete.
The finished surface of shotcrete is generally a bit rougher than with cast-in-place concrete. Because of this, most shotcrete pools have a finished surface consisting of a pool plaster material or Diamond Brite as opposed to epoxy-based pool paint.
It is not that epoxy pool paint is better than pool plaster, it is just a fact that paints generally will not look as good when applied to shotcrete walls as opposed to cast-in-place or gunite concrete with a smoother finish. Most people prefer pool plaster type finishes, but epoxy paint is generally cheaper to initially install.
Like shotcrete, gunite is a form of concrete that is applied to a surface pneumatically. The formula for concrete in a gunite application has a higher percentage of cement and a lower amount of water than that of “cast-in-place” or “shotcrete” concrete. Like shotcrete, the formula results in a concrete mix that is dry enough to be applied to vertical surfaces such as pool walls.
Gunite concrete is often times referred to as “dry gun” concrete. The reason for this label is the dry nature of its application. Unlike cast-in-place and shotcrete, with gunite the dry portions of the concrete are mixed at a concrete plant, or at the jobsite, before being applied. There is no water added to the dry concrete mix until actual application from the gunite nozzle.
Dry gunite machine forces the dry concrete mixture into a hose under air pressure. The dry mixture travels through the hose to a specialized nozzle that is also connected to a water source under pressure. The dry concrete is combined with the water and mixed through channels in the nozzle before being sprayed onto a preformed surface. The result is a concrete mixture that can be applied extremely dry with a high cement content to bind the aggregate with even greater strength.
Like with shotcrete, the gunite nozzle operator uses a back-and-forth motion to sculpt the pool walls to the shape and thicknesses designed.
The lower volume of water in gunite results in smaller changes in the concrete volume as it hydrates, with a resulting need for much fewer joints.
Like shotcrete, one thing that must be considered when using gunite in pools is the experience factor. It is critical with any construction that the contractor building the pool be highly experience with the methods of construction being used. With gunite, the person operating the gunite hose and nozzle is the absolute key to getting a great result from the concrete.
When done properly, gunite results in a much stronger and watertight installation than with cast-in-place. Gunite will result in even stronger concrete than shotcrete.
Pros
When properly designed and constructed, gunite will result in the strongest and most watertight concrete pools possible.
Because of the lower volume of water used in the concrete mixture, there is less volume change through water hydration, which results in much fewer joints in the pool. Remember the rule of thumb for good pool design and construction is to “minimize the number of pool joints between concrete sections in the pool.”
Higher compressive strengths than cast-in-place or shotcrete concrete. Typical compressive strengths of gunite are in the range of 7,500 to 9,000 psi.
Properly constructed gunite has a smooth enough surface to be finished by epoxy-based paints or pool plasters.
“Free form” application makes it possible to build very strong and watertight structures of any shape.
Cons
Like all concrete installation, the contractor must be experienced and skilled in the particular technique of installation. There are even fewer people skilled in the use of gunite than that of cast-in-place or shotcrete concrete.
Construction of pools using the gunite process is somewhat more time consuming than shotcrete, which usually results in a slightly higher construction cost.
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