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RollerRoller--Compacted Concrete Pavement:Compacted Concrete Pavement:Applications, Design, Construction, & Quality ControlApplications, Design, Construction, & Quality Control
ROAD SCHOOL
March 11, 2009
RCC PavementRCC Pavement
• Definition
• Applications
• Design
• Construction
•Quality Control
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DefinitionDefinition“Roller-Compacted Concrete (RCC) is a no-slump concrete that is compacted by vibratory rollers.”concrete that is compacted by vibratory rollers.
• Zero slump (consistency of DGA)• No forms• No reinforcing steel • No finishingNo finishing• Consolidated with
vibratory rollers
Concrete pavement placed in a different way!
Benefits of RCCPBenefits of RCCP
EconomicalEconomicalHigh load carrying abilityHigh load carrying abilityEliminates rutting and spans weak subgradesEliminates rutting and spans weak subgradesExcellent freezeExcellent freeze--thaw durability thaw durability Simple, fast constructionSimple, fast constructionHi h d ti ith i i l bHi h d ti ith i i l bHigh production with minimum laborHigh production with minimum laborLight surface reduces lighting requirementsLight surface reduces lighting requirements
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Logging YardsLogging Yards
Intermodal YardsIntermodal Yards
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Distribution CentersDistribution Centers
18 acre distributioncenter in Austin, TX
10 years after construction
Warehouse FacilitiesWarehouse Facilities
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Parking AreasParking Areas
134 acre parking lot at Saturn Plant, TN (1988-89)
200 acre parking lot at Honda Plant, AL (2004)
Streets & RoadsStreets & Roads
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Highway ShouldersHighway Shoulders
I-285 Atlanta, GA
Use is GrowingUse is Growing
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Engineering PropertiesEngineering Properties
Compressive strengthCompressive strength4,000 to 10,000 psi4,000 to 10,000 psi
Flexural strengthFlexural strength500 to 1,000 psi500 to 1,000 psiffrr = C(f’= C(f’cc))1/21/2
Modulus of ElasticityModulus of ElasticityModulus of ElasticityModulus of Elasticity3,000,000 to 5,500,000 psi3,000,000 to 5,500,000 psiE = CE = CEE(f’(f’cc))1/21/2
Thickness Design of RCC Thickness Design of RCC PavementsPavements
Follo s rigid pa ement design methodsFollo s rigid pa ement design methodsFollows rigid pavement design methodsFollows rigid pavement design methodsPlain, undoweled, unreinforced concrete Plain, undoweled, unreinforced concrete pavementpavementPCA’s PCA’s Structural Design of RCC for Structural Design of RCC for Industrial PavementsIndustrial PavementsIndustrial PavementsIndustrial PavementsPCA PCA RCCRCC--PAVE PAVE ProgramProgram
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Mix DesignMix Design
Differs from conventional concrete mixture Differs from conventional concrete mixture proceduresprocedures
Not airNot air--entrainedentrainedLower water contentLower water contentLower paste contentLower paste contentLower paste contentLower paste contentLarger fine aggregate contentLarger fine aggregate contentNominal maximum size aggregate (NMSA)Nominal maximum size aggregate (NMSA)
+/+/-- 5/8”5/8”
Mix DesignMix Design
Dry enoughDry enoughDry enoughDry enoughto support ato support avibratory rollervibratory roller
Wet enoughWet enoughto permitto permitto permitto permitadequate adequate distributiondistributionof pasteof paste
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Aggregate SelectionAggregate Selection
Aggregate Aggregate gg ggg gselection very selection very importantimportantResponsible for Responsible for mix workability, mix workability, segregation, ease segregation, ease of consolidationof consolidationof consolidationof consolidationPrePre--blended or blended or stored separatelystored separately
Cementitious MaterialsCementitious Materials
Select materials based upon availabilitySelect materials based upon availabilitySelect materials based upon availability, Select materials based upon availability, economics, and design requirements:economics, and design requirements:–– Portland cement: Type I or IIPortland cement: Type I or II–– Fly ashFly ash–– Normally 500 lb/cy cementitious (12% to 17% Normally 500 lb/cy cementitious (12% to 17%
of dry weight)of dry weight)y g )y g )–– If used, fly ash proportions are typically 15% to If used, fly ash proportions are typically 15% to
25%25%
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AdmixturesAdmixtures
Retarder or water reducer can be used to Retarder or water reducer can be used to increase working timeincrease working timeAir entrainment not yet technologically Air entrainment not yet technologically possible, butpossible, but–– Experience has shown RCC can be made Experience has shown RCC can be made
freeze/thaw resistantfreeze/thaw resistantfreeze/thaw resistantfreeze/thaw resistant–– It’s too dense to be saturatedIt’s too dense to be saturated
Soil Compaction MethodSoil Compaction Method
Determine moisture contentDetermine moisture contentDetermine moisture contentDetermine moisture content–– Construct moisture/density curveConstruct moisture/density curve–– Modified proctor ASTM D1557Modified proctor ASTM D1557–– Assume a median cement content (e.g. Assume a median cement content (e.g.
15 percent)15 percent)15 percent)15 percent)
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Standard vs Modified ProctorStandard vs Modified Proctor
ConstructionConstruction
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Continuous Pug MillContinuous Pug Mill
HighHigh--volume volume applicationsapplicationsExcellent mixing Excellent mixing efficiency for dry efficiency for dry materialsmaterials250 to 500+ tons/hr250 to 500+ tons/hrMobileMobileMobileMobileErected on siteErected on siteHigher mobilization Higher mobilization costscosts
High Volume ProductionHigh Volume Production
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Central Concrete Batch PlantCentral Concrete Batch Plant
Highly accurateHighly accurateHighly accurate Highly accurate proportioningproportioningLocal availabilityLocal availabilitySmaller output capacitySmaller output capacityLonger mix times than Longer mix times than conventional concreteconventional concreteFrequent cleaningFrequent cleaningDedicated productionDedicated production
Low Volume ProductionLow Volume Production
Clifton Road Union County, INClifton Road Union County, IN
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TransportingTransporting
Dump trucksDump trucksDump trucks Dump trucks normally usednormally usedCovers required Covers required for long hauls, or for long hauls, or hot/windy hot/windy conditionsconditionsconditionsconditions
Subbase/Subgrade PreparationSubbase/Subgrade PreparationSame requirementsSame requirementsSame requirementsSame requirementsas conventional concreteas conventional concreteMust be stiff to provide Must be stiff to provide full compactionfull compactionStable subgradeStable subgradeNonNon--pumping subbasepumping subbaseMoisten subbase priorMoisten subbase priorto RCC placementto RCC placement
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Placing EquipmentPlacing Equipment
High density paversHigh density pavers–– Vibrating screedVibrating screed–– Dual tamping barsDual tamping bars–– High initial densityHigh initial density
(90% to 95%)(90% to 95%)–– Reduces subsequent Reduces subsequent
compactioncompaction–– HighHigh--volume placementvolume placementHighHigh volume placement volume placement
(1000 (1000 -- 2000 tons/shift)2000 tons/shift)–– Designed for harsh mixesDesigned for harsh mixes–– Smoothest RCC surfaceSmoothest RCC surface
High Density PaversHigh Density Pavers
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Placing EquipmentPlacing Equipment
Conventional Conventional Asphalt PaversAsphalt Pavers
–– Provides some Provides some initial density (80%initial density (80%--85%)85%)
–– Relatively smooth Relatively smooth surfacesurface
CompactionCompaction
Proper compaction isProper compaction isProper compaction is Proper compaction is critical for strength and critical for strength and durabilitydurabilityCompact to 98% of Compact to 98% of modified Proctormodified ProctorVibratory rollerVibratory rollerNonNon--vibratoryvibratoryyysteel wheel rollersteel wheel rollerRubberRubber--tire rollertire roller
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CuringCuringExtremely important forExtremely important forsurface durabilitysurface durabilityLow moisture in RCCLow moisture in RCCThree methods:Three methods:–– Moist cureMoist cure–– Concrete curing compoundConcrete curing compound–– Asphalt emulsionAsphalt emulsion
Construction JointsConstruction JointsMost critical area of projectMost critical area of projectMust be constructed properly for durabilityMust be constructed properly for durabilityMust be constructed properly for durabilityMust be constructed properly for durabilityEnsures bond/interlock, so slab acts monolithicallyEnsures bond/interlock, so slab acts monolithicallyThree types ofThree types ofconstruction joints:construction joints:–– “Fresh joints”“Fresh joints”
“C ld j i t ”“C ld j i t ”–– “Cold joints”“Cold joints”–– “Horizontal joints”“Horizontal joints”
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Fresh JointFresh Joint
Tight Fresh JointTight Fresh Joint
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Cracking / JointingCracking / JointingSawSaw--cut joints cut joints unnecessary forunnecessary forunnecessary for unnecessary for performanceperformanceNatural cracks provide Natural cracks provide excellent load transfer excellent load transfer due to aggregate due to aggregate interlockinterlockSS t j i t t lt j i t t lSawSaw--cut joints control cut joints control cracks for aesthetic cracks for aesthetic purposespurposes
Natural CracksNatural Cracks
M t i lM t i lMost economicalMost economical~30ft spacing~30ft spacingOften first cracks Often first cracks appear within 24 hoursappear within 24 hoursNarrow crack widthsNarrow crack widthsSeal if > 1/8Seal if > 1/8--inchinchSeal if > 1/8Seal if > 1/8 inchinchBest load transferBest load transferMinimal ravelingMinimal raveling
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SawSaw--Cut JointsCut Joints
More aesthetically More aesthetically pleasingpleasingEarly entry saws very Early entry saws very effective, shortly effective, shortly following placementfollowing placementNeed to saw withinNeed to saw within12 hours to avoid 12 hours to avoid
t ll d kit ll d kiuncontrolled crackinguncontrolled cracking1/3 to 1/4 of total1/3 to 1/4 of totallayer thicknesslayer thickness
SurfacingSurfacingPaverPaver--placed RCC needs no surface for placed RCC needs no surface for durabilitydurabilityAdequate for lowAdequate for low--speed trafficspeed trafficHighHigh--density pavers can provide smoothness density pavers can provide smoothness for mediumfor medium--speed trafficspeed trafficThin asphalt surface (1Thin asphalt surface (1--1/2 to 3 inches)1/2 to 3 inches)–– Improves surface for highImproves surface for high--speed trafficspeed traffic–– Improves surface for highImproves surface for high--speed trafficspeed traffic––Placed immediately or any time thereafterPlaced immediately or any time thereafter
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Surface TexturesSurface Textures
TestingTesting
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Moisture / DensityMoisture / Density
Nuclear GaugeASTM C1040
Strength TestingStrength Testing
Fabricating CylindersWith Vibrating Hammer
ASTM C1435
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ThicknessThickness
Indiana ProjectsIndiana Projects
Essroc Cement Plant
Speed, INHenry County
Clifton Rd., Union Co. Browning/Duke Property
Hendricks Co.
St. Joseph County
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for additional information, please visit PCA’s website at
www.cement.org/pavements
