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Shotcrete

What is Shotcrete

Definition of shotcrete according to the National Building Regulations Organization:

Shotcrete is a concrete spray with dry or wet materials sprayed on the desired surfaces at high speed through a compressed air stream. Due to high pressure and velocity, it is compacted dynamically. As a result, a dense, self-supporting, and load-bearing layer is formed. Shotcrete is commonly employed as a makeshift storage system, and in some cases, a permanent cover.

Sprayed concrete (gunite) is not a new invention. The first experience of using dry matter spraying for new structures dates back to 1907 in Pennsylvania by an American taxidermist named Carl Ethan Akeley.

The use of shotcrete is prevalent across the world today. It is believed that the development of technology in the future will result in a more mixed spraying process, including a new generation of additives, concrete reinforcers, micro silicates, polypropylene, and steel fibers for sprayed concrete.

Shotcrete Uses

Shotcrete is employed in various concrete works, the most notable of which are the following:

Execution of different concrete operations, such as the construction of swimming pools, maintaining walls, large concrete tanks, lining tunnels, dams, irregularly shaped concrete structures, etc.

Operation of concrete structures, including repairs, reinforcement, optimization, works of art and decoration, and stabilization of protective coatings.

See Shotcrete products

Shotcrete machine (dry sprayer)

Mortar sprayer (wet sprayer)

Fire-proof material device

Slurry injection machine

Received certificates

Shotcrete device features

Spiral wet spraying machines

Ability to spray fire-proof materials
Excellent performance for 3D panel walls
Equipped with different nozzle heads
Easy to wash and clean
Ability to adjust the stator
With an initial mixer
Tank net
1 to 5 mm granulation
Equipped with air compressor

Dry spraying machines

Grease absorber rubber plate
High capacity input hopper
8 to 15 mm granulation
Easy to move
Ability to change the output volume
High-flow material transport
Easy service
Ability to run wet and dry shotcrete
Equipped with automatic lubrication system

Piston spraying machines

Electric and diesel propulsion
High-capacity tank
6 to 8 mm granulation
Easy to move
Different nozzle heads
Pumping up to a height of 100 meters
Ability to change the pumping status
Wet shotcrete
Equipped with anti-wear hose

Shotcrete parts

Delivery across Iran

Questions and answers about the cement sprayer

Question 1: How high does it pump?

Answer: Mardoni pumps: from 5 to 6 floors (15-20 meters).
1-phase piston pumps: 7 floors (20-25 meters),
And 3-phase piston pumps: up to 15 floors.

Question 2: How many meters of the hose can we add to the device?

Answer: Mardoni pumps: up to 50 meters
Piston pumps model T13-M: up to 70 meters, and model T13 series B: up to 150 meters.

Question 3: Does this device work with 1-phase electricity?

Answer: Only the T13-M piston pump is suitable for operation with 1-phase electricity and pumps up to 7 floors.

Question 4: How many people are required to operate the device?

Answer: Usually from 3 to 5 people, depending on the working conditions and the desired area.

Question 5: What is the weight and volume of the devices?

Answer: Mardoni pumps without a mixer: 250 kg, and with primary mixer: 350 kg
Piston pumps 420 kg and large model 680 kg

Question 6: How much do consumable parts cost?

Answer: Mardoni pumps, if used with fine-grained, i.e., up to 3 mm (average): 1.5 million Tomans for 200 square meters of operation with a thickness of 3 cm. If the granulation is larger (the thickness of the sand is 5 to 6 mm), this cost is per 1000 meters

Question 7: How many meters can be cemented per day?

Answer: It depends on various factors, including the type of device, the number of people, etc.
Mardoni pumps with 3 to 5 people: 150 meters to 200 meters
Piston pumps with 3 to 5 people: 200 meters to 400 meters

Question 8: Is this machine suitable for spraying fine particles?

A: Yes. Nevertheless, it is recommended to use Mardoni pumps or mono-pumps (due to more suitable output and uniform spraying).

Question 9: What is the rate of return on investment of the device?

Answer: It depends on many factors, but usually, if the work is suitable with price and area, the rate of return is about two months.

Question 10: How many centimeters of mortar can the machine pump?

Answer: In each model of the device, the thickness depends on the nozzle. The minimum thickness is 5 mm, and the maximum thickness is up to 50 cm and even higher.
If spraying with high thicknesses is required, it is finally necessary to spray in several stages.

Question 11: From what distance does the mortar machine spray?

Answer: It varies depending on the pump pressure and the desired level. Spraying is usually from a distance of 50 cm.

Question 12: Can concrete be injected?

Answer: No. If concrete means coarse-grained, for example, 15 to 25 mm, this is not possible.
Moreover, up to 3 mm grain size is finally possible for Mardoni pumps with this type of pump. Also, up to 6 mm grain size is allowed for T13-M piston pumps, and finally up to 10 mm for some piston pump models.

Question 13: Can additives be added to the mortar inside the machine?

Answer: Authorized additives can be used to work with any device, including Lubricants – Super-lubricants – Micro-silica powder – Micro-silica gel – Sealing materials – Quick-setting – Antifreeze – Polymeric materials – Glass and polymer fibers, and any similar materials.

Question 14: Is the device suitable for fire protection spraying?

Answer: Yes. Mardoni pumps are suitable for this purpose and have better performance compared to other devices.

Question 15: How many types of nozzles does the device have?

Answer: There are different nozzles, and different nozzle heads can be replaced according to the type of material used and the thickness required for spraying. Moreover, if necessary, a special nozzle is designed and manufactured.

Question 16: Is the machine suitable for spraying gypsum?

Answer: No. None of the piston and mortar devices are suitable for spraying gypsum.
The only machine that can spray plaster is the T4 plastering machine.

Question 17: Does the device have training and installation?

Answer: Yes. Training and installation are done in person by the company’s expert at the buyer’s project site.

Question 18: How granular is the machine capable of working?

Answer: Mardoni pumps from 1 to 3 mm are the best granulation that does not have much depreciation, but their depreciation will increase if the granulation is larger.
Piston pumps can easily pump from 1 mm to 6 mm, and some models can pump up to 10 mm.

Question 19: Does the machine need screeding?

Answer: If screeding is needed, yes. Because the machine only does the spraying work.

Question 20: Does the device have a warranty?

Answer: Yes, there is a 1-year warranty and a 10-years after-sales service.
The warranty includes the main parts of the pump.

Question 21: What is a machine suitable for other than cementing?

Answer: Spraying fine particles – Mortar injection – Grout injection – Slurry injection – Mortar transfer – Roof slope – Soil spraying in excavations – Road trenches and the like.

Question 22: How to move the device?

Answer: It can be loaded into a van and towed by a crane or tow. The choice depends on the distance traveled.

Question 23: What is the size of the hose in inches?

Answer: For Mardoni and piston pumps, T13-M size 1.5 inch is used for the whole route.
For B-series piston pumps, a 2-inch hose is used. Furthermore, for the working nozzle, a 1.5-inch hose is used.

Question 24: Does the device need an air compressor?

Answer: No, an air conditioning system is installed on the sprayers, and there is no need to supply air from outside unless we want to increase the pressure of spraying the materials.

Question 25: What is a mortar sprayer?

Answer: In the mortar spraying machine, we transfer the mortar to the tank of the machine after mixing. The mortar is then pumped through a hose and sprayed by the person (nozzle man) to the desired surface due to the compressed air.

Question 26: What is the capacity of the tank?

Answer: 130 liters to 180 liters.

Production of various parts for Shotcrete and mortar sprayer
Produced by industrial units.
To support national manufacturers, you can refer your orders to the sales department, and after final processing, they will be sent to you as soon as possible