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Modeling of Shotcrete Application for Use in a Real‐Time Training Simulator

Simulators provide significant advantages in training operators of concrete spraying machinery, such as economic savings, the practical absence of safety risks, and environmental and educational benefits. The main challenge in developing a real‐time training simulator for concrete spraying machinery lies in the modeling of shotcrete application. This article presents a novel method that models and simulates in real time the three main factors influencing shotcrete sprayability: adhesion, cohesion, and rebound. Furthermore, thanks to the addition of an obstacle model, the method makes it possible to spray onto additional supporting elements, which is a typical shotcrete application. The proposed method considers a wet‐mix thick flow spraying process and is based on experiments that were run with a real concrete spraying machine and complemented by expert advice. The method was developed and evaluated using a user‐centered methodology, resulting in realistic shotcrete application modeling that meets the needs for training concrete spraying machinery operators.