Shotcrete (Dry Mix)
Dry-mix shotcrete conveys dry material by air and hydrates at the nozzle, providing a versatile concrete application method ideal for remote sites, repair work, and intermittent applications where portable equipment and adjustable water content are advantages.
Understanding Shotcrete (Dry Mix)
Dry-mix shotcrete conveys dry material by air and hydrates at the nozzle, providing a versatile concrete application method ideal for remote sites, repair work, and intermittent applications where portable equipment and adjustable water content are advantages.
The experienced nozzleman controls water addition for optimal consistency—particularly valuable for overhead work and variable substrate conditions.
This technique is used in our services for:
Shotcrete Typical Applications
How It Works
Our proven methodology ensures consistent, high-quality results for every installation.
Equipment Setup
Position portable dry-mix gun, connect air and water lines at nozzle.
Surface Preparation
Clean substrate, install reinforcement and drainage as required.
Application
Nozzleman adds water at gun while applying in layers with proper technique.
Curing
Apply moist curing or curing compound to ensure proper hydration.
Key Advantages
Equipment Portability
Compact dry-mix guns can be transported to remote sites where concrete trucks cannot access.
Water Control
Nozzleman adjusts water content in real-time for optimal consistency on varying substrate conditions.
Intermittent Work
Dry material can be stopped and started without waste—ideal for small areas or interrupted work patterns.
Overhead Excellence
Dryer mix with less slump is preferred for overhead and vertical applications with minimal sag.
Lower Mobilization Cost
Smaller equipment and bagged material reduce mobilization costs for small-scale projects.
Technical Considerations
Soil/Rock Conditions
Substrate must be clean, sound, and dampened for bond. Loose material removed before application.
Groundwater
Dryer mix can be applied in damp conditions. Active water requires grouting or diversion before shotcrete.
Load Capacity
Structural capacity determined by thickness, reinforcement, and verified strength. Test panels required for structural applications.
Spacing
Not applicable for shotcrete facing. Construction joints as needed for work sequence.
Installation Method
Dry material conveyed by compressed air; water added at nozzle by experienced nozzleman. Applied in lifts of 1-2 inches.
Equipment Used
- Dry-mix shotcrete gun
- Air compressor (adequate CFM)
- Water supply with pressure
- Pre-bagged dry mix or site batching
- Reinforcement and accessories
Limitations
- Higher rebound than wet-mix
- Lower production rate than wet-mix
- Dust generation requires control
- Nozzleman skill critical for quality
Technical Specifications
System Variations
Gunite
Traditional term for dry-mix shotcrete using fine aggregate mix.
Best For:
- Pool construction
- Repair work
- Thin sections
Fiber-Reinforced Dry Mix
Synthetic or steel fibers added to dry mix for crack control.
Best For:
- Slope protection
- Tunnel repair
- Thin structural sections
Accelerated Dry Mix
Quick-setting additives for rapid strength gain and water control.
Best For:
- Active water conditions
- Emergency repairs
- Overhead work
Integration With Other Systems
Rock Bolting
Dry-mix shotcrete provides surface protection between rock bolt locations.
Learn MoreWire Mesh
Welded wire mesh reinforcement embedded in dry-mix shotcrete for crack control.
Weep Drains
Drainage provisions installed before or through shotcrete facing.
Learn MoreExample Project Types
- Tunnel repair and rehabilitation
- Remote slope stabilization
- Concrete structure repair
- Small retaining walls
- Canal and channel lining
- Mine support applications
- Emergency repairs
Our Work in Action
Why Choose Rock Supremacy for Dry-Mix Shotcrete
Remote Access Capability
We transport dry-mix equipment to sites where concrete trucks cannot reach.
Experienced Nozzlemen
Skilled operators with years of dry-mix experience deliver consistent quality.
Flexible Scheduling
Dry-mix equipment allows efficient work on intermittent or phased projects.
Overhead Expertise
Proven capability for tunnel crowns and overhead applications requiring dryer mixes.
Our Work
See how we've applied this technique and others to solve real-world geotechnical challenges.
Moffat Tunnel Portal Rehabilitation
Structural rehabilitation of the historic Moffat Tunnel portal including rock bolting, shotcrete, and drainage improvements.
Pacific Coast Highway Protection
Emergency scaling and installation of 500 rock bolts to secure a failing bluff face threatening Highway 1.
Roseville Rail Yard Tunnel Repair
Emergency structural repair of a failing rail tunnel crown in one of the West Coast's busiest rail yards.
Shotcrete (Dry Mix) FAQ
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Related Techniques
Explore other engineering methods we use to deliver comprehensive geotechnical solutions.
Rock Bolting
Rock bolting stabilizes fractured, jointed, or unstable rock masses by anchoring steel bars deep into competent rock. By tying loose blocks back to stable substrate, rock bolts improve the overall strength and cohesion of slopes, cuts, tunnels, and vertical faces.
Shotcrete (Wet Mix)
Wet-mix shotcrete is pre-batched with water and pumped to the nozzle where compressed air propels it onto surfaces. This method delivers consistent mix quality, high production rates, and minimal dust—preferred for structural applications and high-volume projects.
Structural Shotcrete
Structural shotcrete is high-strength, reinforced concrete applied pneumatically to create durable retaining walls, tunnel linings, and slope support systems. Engineered to carry significant loads, it provides monolithic construction that conforms to irregular surfaces.
Weep Drains
Weep drains provide surface-level drainage relief by allowing water trapped behind shotcrete, retaining walls, or stabilized slopes to escape. These drains prevent hydrostatic pressure buildup, which can compromise structural stability.