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Mix Design & Construction of RCC
Wayne Adaska, P.E.Director, Public WorksPortland Cement Association
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Dry enough tosu ort vibratorroller
Wet enough topermit adequatedistribution of paste
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Not air-entrained
Lower water content
Lower paste content
Nominal max. size aggregate +/- 5/8 in.
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evera me o s ava a e:
Soil compaction methods
Optimal paste volume method
Solid suspensions model
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Aggregate selectionvery important
Responsible for mix
workability,segregat on, ease oconsolidation
re- en e orstored separately
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Aggregate Selection
Select a sound, well- raded a re ate
For stability under vibratory roller, aggregateinterlock for load transfer, hi hest densit ,reduced segregation
Crushed or uncrushed ravel or crushed stone
Crushed aggregates:
Require more water
rov e grea er s a y, ess segrega on
Provide higher flexural strength
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Aggregate Selection
,
aggregates can be used.
Provides smooth surface, reduces segregation
Economic advantage using non-washed and pit-runaggregates including dense graded aggregate base
Provide adequate stability under vibratory roller
2%-8% passing #200 sieve
Supplements paste to fill voids and maintain tight surface
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Optimum Combined Gradation(Shilstone Method)
The Coarseness Factor Chart provides on
The 0.45 Power Chart shows a trend
Percent of aggregate retained on
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Sieve Size Percent Passing Actual
in mm Minimum Maximum Gradation
1" 25 100 100 100
"
1/2" 12.5 75 90 85.2
3/8" 9.5 65 85 75.0. .
#8 2.36 25 50 43.5
#16 1.18 20 40 34.2
#30 0.6 10 30 24.3
#50 0.3 7 20 10.6
. .
#200 0.075 2 8 0.7
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Coarseness Factor (CF) = % retained on 3/8 in. % retained on # 8 sieve x 100
Workability Factor (WF) = % passing #8 sieve + [ 2.5 x (lb/yd3
of cementitiousmaterial 564) / 94]
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Select cementitious materials
Blended cement: (C595 or C1157)
,(C1240)
-(12% to 17% of dry weight)
,
25%; silica fume typically 5% to 10%
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Determine moisture content
Modified proctor ASTM D1557
ssume a me an cemen con en e.g.500 pcy)
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-
144
143
144
lb
141
142
De
ty(
140
141
2% 3% 4% 5% 6% 7% 8%
Dry
2% 3% 4% 5% 6% 7% 8%Moisture Content
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e erm ne cemen ous ma er a s con en
Use optimum moisture content
Run cement series
e.g., 11%, 13%, 15%, 17%Select cement content which yields
appropriate strength.
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.
6,000
6,500
sve 725
697
5,500
Cmpe
nh(p
667
4,500
,
2DaC
Se
603
4,00010% 12% 14% 16% 18%
Cement Content
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e ar er or wa er re ucer can e use oincrease working time
Silica fume (7%) has resulted in
significant strength gainsAir entrainment not yet technologically
ossible, but
Experience has shown RCC can be madefreeze/thaw resistant
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Freeze-Thaw Durability
Field performance excellent, although not air
Minor surface paste (1/16) erodes, thensta zes
RCC results variable under ASTM C666 (F/T)and C672 (Deicer scaling)
Tests a ear to be too severe based on
actual experience
and precast units possibly more appropriate
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Freeze-Thaw Durability
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Sample RCC Mix Designs
Port of Tacoma
Units Intermodal Yard CTL Mix Canada Mix
Coarse Aggregate lb/cy 1,700 2,106 2,210Fine Aggregate lb/cy 1,700 1,378 1,338
% Finer Than #200 % 3 - 7 2 1
Cement lb/cy 450 504 470
Fly Ash lb/cy 100 0 36 (silica fume)
Admixture oz/cwt none none 5 (WR)
w/c ratio - 0.47 0.42 0.34
Unit Weight lb/cy 154.3 152.0 153.1
ompress ve: ay ps , , -
Compressive: 28 day psi 6,050 7,900 -
Flexural: 3 day psi 525 690 1,205
Flexural: 28 day psi 770 900 1,640
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Construction
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Subgrade preparation
Mixin rocess
Transporting
Compacting
JointingCurin
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Continuous Pug Mill
High-volume
Excellent mixing
materials
2 + n hr
Mobile, erected on site
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Highly accurateproportioning
Local availability
Smaller outputcapacity
Longer mix times than
conventional concreteFrequent cleaning
Dedicated production
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Highest local availability2-ste rocess
Feed into transit
mixersDischarge into dumps
Frequent cleaning
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Dry Concrete Batch Plant
mixer can aid inthorough mixing andplant throughput.
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Mobile Mixers
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Transporting
Rear dump trucksnormally used
Minimize transport
timeCovers required for
long hauls, or
o w n y con ons
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Transporting
Load in multiple piles
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Placing
La er thickness
4 in. minimum8 in. maximum 10 in. with heav -dut avers
Timing sequence
fresh joint, unless retarders used
Production should match paver capacity
u u w
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Placing Equipment
Hi h-densit aversVibrating screed
Dual tamping bars
Hi h initial densit 90-95%
Reduces subsequentcompaction
High-volume placement(1,000 to 2,000 cubic yardsper shift)
Designed for harsh mixes
Smoothest RCC surface
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Placement Equipment
Transfer equipment keeps paver fully charged
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Placing Equipment
Conventional asphalt pavers
Provide some initial density(80-85%)
Relatively smooth surface
May require modification
Increased maintenance
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Compaction
is critical for strengthand durabilit
Compact to 98%
Modified ProctorVibratory roller
Rubber-tire roller
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Must be constructed properly for durability
nsures on nter oc , so s a actsmonolithically
ree ypes o cons ruc on o n s:
Fresh joints
Horizontal joints
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Compaction more difficult
Segregation more likely
Try to minimize number of cold joints
Care needed to match rade from coldto fresh joint
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Edge Compaction
Compacting shoeompacting shoe
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-
unnecessary forerformance
Natural cracks provide
excellent load transferSaw-cut joints control
cracks for aesthetic
purposes
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Most economical
15 to 60 ft spacing
Often first cracksappear within 24 hours
arrow crac w s
Seal if > 1/4 in.
Minimal raveling
New, Unsealed
Crack
10-yr Old
Sealed Crack
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Saw-Cut Joints
More aesthetically
pleasing- ,
shortly following
lacementNeed to saw within 12
hours to avoid
uncon ro e crac ng 1/3 to 1/4 depth
conventional concrete
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Curin
Ensures surface durability; reduces dusting
Low moisture content in RCC; no bleed water
Moist cure
Asphalt emulsion
W C
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Water Cure
Typically 7-day specified
C C i C d
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Concrete Curin Com ound
White-pigmented concretecuring compounds
Application rate dependson surface texture
Surface Texture
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Surface Texture
Intermodal Yard, TX
Sludge Drying Bed, TX
Honda, ALarehouse Facility, WI
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Quality Control
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,
Plant calibration
Density tests
SmoothnessSurface texture
Strength
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ASTM D1557
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ASTM C1435
ASTM C1435
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Typically 3/8 in. over 10-ft length
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More Information
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www.cement.org/pavements
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Questions?Discover how beautiful concrete can be
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Prescriptive: Provides required properties,
and the method of installation.
Performance: Provides the required results,
criteria by which the performance will bejudged and the method by which it will beverified.
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ggrega e gra a on
T e of mixin lant
Type of paver
Type and size of compaction equipment
Method of curing
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Minimum strength
Pr i n r
Thickness
Smoothness
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Mix design/Compressive strength
Type of mixing plant/Production rate
Type and size of compactor/Density
Minimum number of passes/Density