Shotcrete Crews

Shotcrete is concrete sprayed at high speed onto surfaces such as pool shells, tunnels, retaining walls and slopes. Crews work with pressurized hoses and abrasive material flying back at them, often from scaffolds or in confined areas.

• Nozzle Operators
• Pump Operators
• Finishers

Hazards

• Hose whip and blockages: a blocked line can burst or whip when pressure is released. See Concrete Pump Operators.
• Rebound: material bouncing off the surface strikes the crew and creates dust.
• Silica dust from dry-mix shotcrete. See Silica.
• Cement burns from wet concrete on skin and in eyes. See Wet Cement & Concrete Burns.
• Falling or sloughing material from overhead and walls; unstable ground. See Soil Nailing & Shotcrete Walls.
• Falls from scaffolds and slopes.
• Noise, air compressor hazards and electrical hazards.
• Confined space and ventilation in tunnels and pools. See Tunnel Workers.

Controls

• Never point the nozzle at anyone. The nozzle operator controls it with a clear stance and a helper to support the hose. Use agreed signals for starting and stopping.
• Use whip checks or hose restraints at couplings, rated hoses and clamps. Inspect hoses and fittings each shift.
• To clear a blockage, release pressure fully before disconnecting the hose; keep everyone clear of the line's end. Never hit a pressurized line.
• Keep workers out of the rebound and overspray zone, and out from under the area being sprayed.
• Use wet-mix shotcrete rather than dry-mix where possible, and add water or dust suppression.
• Wear a hard hat, face shield and safety glasses or goggles, respirator, waterproof gloves and boots, long sleeves and hearing protection.
• Wash cement off skin quickly and flush eyes if splashed.
• Provide stable platforms, guardrails and fall protection. Barricade the work area.

Checklist

• Pump, hose and compressor inspected
• Signals and communication agreed between nozzle and pump operator
• Ground and walls checked for loose material before spraying
• Dust controls and respirators in use
• First aid and eyewash available

Last updated: October 8, 2026