Material delivery begins at the batch plant or an on-site continuous mixer. Plant-batched ready-mix concrete is delivered by truck to the pump hopper, with a typical small-aggregate mix (3/8 inch top size) proportioned for pumpability and placement. Where ready-mix delivery is not practical, an on-site continuous mixer (auger or pug mill type) batches material from bagged or silo-stored cement and aggregate as the work progresses. Mix designs are governed by ACI 506R guidance, with verified compressive strength typically 4,000 to 8,000 psi and the project specification calling out slump, air content, and aggregate gradation.
Pumping is the heart of the wet-mix process. Piston pumps deliver high-volume placement (15 to 30 plus cubic yards per hour) for large-scale work, while progressive-cavity (rotor-stator) pumps serve smaller crews and longer hose runs. Delivery hose runs of several hundred feet horizontal and tens of feet vertical lift are routine, allowing wet-mix application well beyond truck access. At the nozzle, compressed air is introduced at the manifold, providing the placement velocity (typically 60 to 100 mph at the nozzle exit) that consolidates the material against the substrate and behind every reinforcing bar. Accelerator, when used, is metered into the material stream at the same point.
Placement discipline mirrors all structural shotcrete work. The nozzleman holds the gun approximately perpendicular to the face at a 3 to 6 foot standoff, applying material in lifts of 2 to 4 inches per pass. Reinforcement is encapsulated by gunning behind every bar from both sides before closing the face, the dominant control on shadow voids that compromise structural integrity. Successive lifts are placed after the prior lift has stiffened, typically 30 to 60 minutes for unaccelerated wet-mix in moderate temperatures. Quality control follows ACI 506.2: production test panels (typically 18 by 18 by 4 inches) are shot alongside the work, cured under matched site conditions, and cored at 7 and 28 days for compressive strength testing per ASTM C1604, with in-place cores from the production work verifying thickness, reinforcement cover, and consolidation.
1
Plant Batching and Delivery
Concrete batched with full water content per ACI 506R proportioning. Ready-mix delivery or on-site continuous mixer feeds the pump hopper.
2
Surface Preparation
Substrate scaled clean and dampened. Edge forms or ground wires set to define face line and total thickness.
3
Reinforcement Placement
Rebar grid, welded wire mesh, or fibers per project structural design. Cover maintained with chairs and spacers.
4
Pumping and Placement
Piston pump conveys mix through hose to nozzle. Compressed air at the nozzle ring (80 to 150 psi) provides placement velocity. Lifts of 2 to 4 inches per pass; encapsulation behind every bar.
5
Quality Control
Production test panels and in-place cores per ASTM C1604 verify strength, thickness, and reinforcement cover under ACI 506.2 acceptance.