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Technical Measures for Preventing Concrete Segregation in Wet-Spray Trolleys
Release time:
2026-05-21
Source:
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Summary:
Concrete segregation is a common issue in wet‑spraying operations, leading to reduced spray quality, increased rebound rates, and accelerated equipment wear. Systematic technical controls and standardized operational management can effectively prevent the occurrence of concrete segregation.
I. Mix Proportion Design and Optimization
Material Proportion Control
Scientific Design of Concrete Mix Proportions:
1. The amount of cementitious material shall not be less than 400kg/m ³, ensure sufficient slurry volume
2. The sand ratio is controlled at 50%-55% Scope: optimize particle gradation
3. The water-cement ratio is strictly controlled at 0.4-0.45 between
4. Add an appropriate amount of fly ash ( 15%-20% ) Improve workability
Admixture Selection
Proper use of functional admixtures:
Select a polycarboxylate-based high-performance water reducer.
Incorporating a thickening agent to enhance the cohesion of the slurry.
Use a slump-retaining agent to maintain workability.
Add fine fillers to fill the voids.
II. Mixing and Transportation Control
Stirring Process Control
Ensure uniform mixing:
Stirring time shall be no less than 90 seconds
The batching sequence shall be strictly followed in accordance with the specifications.
Keep the mixer speed within a reasonable range.
Regularly inspect the wear condition of the mixing blades.
Transportation Process Management
Anti-segregation measures during transportation:
1. The transit time is kept within 1 Within an hour
2. Keep the mixing tank maintained. 3-6r/min Slow rotation
3. Avoid abrupt stops and starts, as well as severe jolts.
4. After arrival, stir rapidly for no less than 2 minute
III. Equipment Operating Procedures
Pumping Parameter Settings
Properly set pumping parameters:
The pumping speed remains stable, avoiding sudden changes.
System pressure is maintained within the rated range.
Adjust the displacement in real time based on the slump value.
Avoid prolonged interruptions in pumping.
Equipment maintenance and upkeep
Maintain equipment in good condition:
1. Regular inspection S Valve and pipe sealing condition
2. Maintain the smoothness of the inner wall of the delivery cylinder.
3. Replace worn piston assemblies promptly.
4. Clean the hopper mixing device.
IV. On-site Construction Management
Spraying Operation Control
Key points for standardizing spraying operations:
Control the spray distance within 1-1.5 Meter range
Keep the nozzle perpendicular to the surface being sprayed.
Adopting a layered spraying process
Control the thickness of single-layer spraying
Environmental Factor Response
Measures for Handling Special Operating Conditions:
1. Implement cooling measures during hot weather.
2. Strengthen waterproofing protection during the rainy season.
3. Optimized Mix Proportion for Long-Distance Pumping
4. Vertically pumped concrete should have its sand ratio appropriately increased.
V. Quality Inspection and Monitoring
Process monitoring
Quality monitoring during construction:
Test the slump and spread of each truck.
Observation of concrete cohesion and water retention
Check for bleeding and segregation.
Record the readings of the pressure gauge and the flow meter.
Finished Goods Inspection
Jet Performance Testing and Evaluation:
1. Rebound index testing
2. Check the flatness of the sprayed surface.
3. Take samples for strength testing.
4. Assess the degree of compaction and uniformity
VI. Development of the Emergency Response Plan
Exception Handling
Emergency measures in the event of segregation:
Slight segregation; adjust the mix proportion and continue using it.
Moderately segregated concrete is returned to the mixing plant for reprocessing.
Severely segregated material shall be disposed of as waste.
Record the causes of segregation and the corrective measures.
Preventive measures have been improved.
Continuous Improvement of Prevention Plans:
1. Analyze the causes of segregation incidents.
2. Optimize mix design
3. Improve construction techniques
4. Strengthen personnel training
VII. Technical Training Management
Operator Training
Enhance Professional Skills:
Master the principles of mix design.
Familiar with equipment operating procedures.
Understand the material’s performance characteristics.
Possess problem-identification skills
Management System Development
Improve the management system:
1. Develop standardized operating procedures.
2. Establish a quality accountability system.
3. Implement a performance appraisal system.
4. Improve technical file management.
Conclusion
Preventing concrete segregation is a critical factor in ensuring the quality of shotcrete operations performed by wet‑spraying rigs. Through scientifically designed mix proportions, standardized equipment operation, rigorous construction management, and comprehensive quality control, the occurrence of segregation can be effectively mitigated. It is recommended to establish a full‑process quality monitoring system, enhance technical training for personnel, and continuously optimize construction procedures to ensure stable and reliable shotcrete quality. At the same time, emphasis should be placed on summarizing practical experience and fostering technological innovation to steadily elevate construction expertise, thereby providing robust assurance for project quality.
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Address: Loudi Avenue, Loudi High-tech Industrial Development Zone, Lianyuan City, Loudi City, Hunan Province
Telephone:400-186-0868
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