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Keywords: cores; cross section; demonstration; encasement; inspection; mockup; nozzleman; nozzter; preconstruction; saw cutting; shotcrete; stripping
forms; test panels. Distrbued 203-8
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Question
Why is a shotcrete preconstruction mockup performed and how is it designed and evaluated? Techstr for

Discussion
The phrase “shotcrete test panels” has been used in the industry to cover a variety of uses in the preconstruction and produc¬
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tion evaluation of concrete placed by the shotcrete method. The purpose of this TechNote is to help the architects/engineers
(A/E) to refine their documents with current use of the terms “mockup” and “test panel” to better define their specific require¬
ments for the project. The majority of this TechNote will focus on the use of shotcrete preconstruction mockup.
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only.

Test panels
The traditional test panels that are often used for obtaining samples for quality control testing purposes during construction
can also be used during the preconstruction phase for acquisition of samples that are used to confirm acceptable performance
of the shotcrete properties in relation to the specified requirements during the approval process. As these panels are gener¬
ally intended to test the compressive strength of the concrete material, they should not include any reinforcing bars or mesh.
Guidance for preparation and testing of specimens extracted from these test panels are presented in ACI 506R, ACI 506.4R,
ASTM C1140/C1140M, and ASTM C1604/C1604M.

Mockups
Mockups are recognized construction industry tools that are often used to demonstrate satisfactory performance prior
to the commencement of construction. Mockups are full-size structural elements or architectural models built to scale for
evaluation. For shotcrete preconstruction testing, they are normally intended to verify satisfactory constructability by simu¬
lating project conditions as well as many of the more difficult features. The cost and effort to build mockups can be sizable.
When mockups are specified, the A/E should consider that the size and complexity of the panels are commensurate with the
project needs.
Mockups are generally project-specific, performed during the preconstruction phase, and are used to determine an acceptable
level of encasement of reinforcement and other embedments. In some cases, mockups can also be used to evaluate form work or
the desired appearance of the finish. Criteria should be specified in the construction documents developed by the A/E.

Designing mockups
The first step in designing a mockup is determining the configuration of the steel reinforcement. The industry standard is to
replicate the worst-case scenario in difficulty for the shotcrete encapsulation of the reinforcing bars. If the nozzleman can, to the
satisfaction of the construction documents, properly encase the reinforcing bar that represents the highest degree of difficulty,
it is generally assumed that the nozzleman will be able to encase less congested areas. It is essential that only the worst-case
reinforcement scenario is represented in the mockup. Two worst-case conditions cannot be morphed together to make a condi¬
tion that is never experienced on the project. When choosing the worst-case scenario, it is important to evaluate not only the
reinforcement but also the wall thickness, formwork, site conditions, and other elements.
There is usually a detail shown on the structural drawings of the reinforcing bar presenting the highest degree of difficulty that
can be incorporated into a mockup. If not, the A/E can list the bar size, cover, and spacing as a separate detail. The orientation
of the shotcrete application may be part of the difficulty and needs to be incorporated into the mockup. Additionally, forming
materials and other components critical to the project (application methods, waterproofing, embedments, and other obstruc¬
tions) can be incorporated into the mockup to allow for demonstration that the shotcrete can be successfully applied to the satis¬
faction of the construction documents. It is allowable that a larger mockup be constructed to allow more than one nozzleman
to be qualified on the larger mockup, such that each nozzleman is placing shotcrete in the same condition while satisfying the
minimum area required to shotcrete a successful mockup.
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2 Shotcrete Preconstruction Mockup—TechNote

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The mockup is then shotcreted by one or more of the same nozzlemen proposed for the project. In addition, the project¬
specific mixture design; material delivery equipment; and, if used, mechanized placement equipment, should also be used when
repoductin
or
shotcreting the mockup. Pertinent means and methods can be evaluated as part of the qualification process. The evaluation
should be conducted by the A/E or an ACI-certified Shotcrete Inspector.
After the concrete reaches sufficient strength, the mockup can be evaluated per the contract documents under direction of the
A/E, which will consist of some combination (or all) of the following:
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a) Stripping forms for visual examination of finished and formed surfaces
b) Cores should be taken per the construction documents following the locations, number, and orientation of cores. This
typically includes removal of cores purposely positioned to cut through reinforcing steel, especially at reinforcing bar
permit d.
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intersections, connections, and laps
c) Review of core samples to assess reinforcing bar encapsulation
d) If necessary, and less common, saw-cut the entire mockup into segments to facilitate visual examination of the entire cross
sections, and any specific areas of interest by

During the process of evaluation, the core samples and mockups should remain at the test site. The location and orientation of
the cores are important information when evaluating the core results. Cores and mockups should be marked during the process
so that each nozzleman and each sample location and orientation can be identified.
ACI 506.6T should be used to determine the ability of the nozzlemen to adequately encapsulate the reinforcement as required.
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Figure 1 shows an example where the A/E has determined the size of the mockup vertically and horizontally and referred to
the most congested reinforcement and thickness. Typically, the size of a preconstruction mockup is 4 x 4 ft, one for each
nozzleman. This example is a good example of how to detail a mockup. Good practices are also shown in the example, for
predetermination of the quantity and the locations of the cores.
Figures 2 through 14 demonstrate typical preconstruction mockups. They also have been rated as per the Application Diffi¬
culty Levels according to ACI 506.4R. These figures are not showing Difficulty Level 1 mockups because it is generally
accepted that they do not require a mockup as long as the nozzleman is certified. As required by ACI 318 and ACI 350, any
shotcrete placement for structural purposes must be placed by an ACI-certified nozzleman.
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Fig. 1 Example of shotcrete wall mockup panel specification.

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Shotcrete Preconstruction Mockup—TechNote 3

Construction of mockups — repoductin materil

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Fig. 2 Typical preconstruction mockup of two layers of reinforc¬
ingsteel to replicate challenging sections for shotcrete applica¬
tion. In this case, there are two panels to qualify two nozzlemen
for the project (Application Difficulty Level 2).
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Fig. 4 Replica made of wood to replicate I-beam shotcrete fire¬
proofing application. Encapsulation of the steel is not difficult
but the shooting angle and access are complicated (Application
Difficulty Level 2). wia.techsrom use
only.

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Fig. 5 Elaborate preconstruction mockup of a tunnel section
with construction details such as reinforcement, waterproofing
membrane, waterstops, and injection tubes. This example indi¬
cates a very expensive and necessaiy situation for an extremely
large and complicated shotcrete installation. This mockup allowed
to qualify multiple nozzlemen. In this case, the mockup was able to
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Fig. 3 Preconstruction mockup construction of a heavily
steel-reinforced section (Application Difficulty Level 3).
verify that shotcrete could be used as final lining instead of cast-
in-place concrete (Application Difficulty Level 3).

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Shotcrete Preconstruction Mockup—TechNote further

Shooting the mockups — repoductin
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Fig. 6 Nozzleman shooting an overhead orientation precon¬
struction mockup (Application Difficulty Level 2).
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Fig. 7 Nozzleman shooting a typical vertical
orientation preconstruction mockup (Application
Difficulty Level 2).

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Fig. 8 Nozzleman shooting a vertical orientation preconstruction mockup with a blow pipe operator to replicate placement methods
(Application Difficulty Level 2).

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Shotcrete Preconstruction Mockup—TechNote

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Finishes There are a great deal of available finishes with the shotcrete method. From a gun finish to exotic architectural repoductin materil
finish, the specifications should clearly spell out what is required. Mockups can then be used to show the quality of the finish
to be expected on the project.
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Fig. 9 Typical preconstruction mockup panel demonstrating
vertical flat v/ood float surface finish for visual inspection.
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Fig. 10—Exposed formed surface after form stripping of mockup for visual inspection.

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6 Shotcrete Preconstruction Mockup—TechNote

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Fig. 11—Gun finish fit is the finish left after the shotcrete is brought to approximate line and grade and left without being disturbed).
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Fig. 12—Architectural finish mockup for visual inspection.

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Shotcrete Preconstruction Mockup—TechNote

Cores and saw cuts

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Fig. 13— Mockups cut by sawing to expose cross section for visual
inspection of the shotcrete consolidation and the reinforcing steel
encasement. Application difficulty level 2, because they were shot
overhead. wu.techsrom
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only.

Fig. 14—Extracted group of cores for visual inspection of the

shotcrete consolidation and reinforcing bar encapsulation on a
thick shotcrete application (Application Difficulty Level 2),

Summary
Mockups allow the Architect/Engineer (A/E) to properly evaluate the overall quality of the application process. They also
provide opportunity to identify potential challenges in shotcrete placement that may be encountered prior to the construction
phase. However, mockups can be complex and time-consuming; thus, they should be clearly defined in the construction
documents.

References
American Concrete Institute
—
ACI 318-19 Building Code Requirements for Structural Concrete and Commentary
ACI 350-20—Code Requirements for Environmental Engineering Concrete Structures and Commentary
—
ACI 506R-16 Guide to Shotcrete
—
ACI 506.4R-19 Guide for the Evaluation of Shotcrete
—
ACI 506.6T-17 Visual Shotcrete Core Quality Evaluation TechNote

A STM International
ASTM Cl 140/C1 140M-11(2019) —Standard Practice for Preparing and Testing Specimens from Shotcrete Test Panels
—
ASTM C1604/C1604M-05(2019) Standard Test Method for Obtaining and Testing Drilled Cores of Shotcrete

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8 Shotcrete Preconstruction Mockup —TechNote

Reported by ACI Committee 506

Simon Reny, Chair James A. Ragland, Secretary
Lars F. Balck Ryan A. Oakes Consulting members
Louis-Samuel Bolduc Ryan E. Poole Jean-Francois Dufour
Chris D. Breeds Raymond C. Schallom Richard A. Kaden
Wem-Ping Nick Chen William L. Snow Sr. Dudley R. Morgan
Scott R. Cumming Jason P. South H. Celik Ozyildirim
William T. Drakeley Jr. Lawrence J. Totten Philip T. Seabrook
Randle M. Emmrich Frank E. Townsend
Antoine Gagnon Marcus FL von der Hofen Liaison members
Charles S. Hanskat Ezgi Wilson Shan Kumar
Marc Jolin Peter T. Yen
Mark R. Lukkarila Lihe Zhang
Axel G. Nitschke

ACI TechNotes are intended for reference for the design and construction of concrete structures. This document is intended for the use of individuals who
are competent to evaluate the significance and limitations of its content and who will accept responsibility for the application of the information it contains.
The American Concrete Institute disclaims any and all responsibility for the accuracy of the content and shall not be liable for any loss or damage arising
therefrom. Reference to this document shall not be made in contract documents.

ACI PRC-506.7-23 was adopted and published April 2023.

Copyright © 2023, American Concrete Institute.

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