ROLLER COMPACTED CONCRETE PAVEMENTpmgsy.nic.in/rcc.pdf · m.p. rural road development authority, project implementaion unit, bhopal roller compacted concrete pavement pilot project

M.P. RURAL ROAD DEVELOPMENT AUTHORITY,PROJECT IMPLEMENTAION UNIT, BHOPAL

ROLLER COMPACTED CONCRETE PAVEMENT

PILOT PROJECT PACKAGE NO.MP-0511

BHOPAL, MADHYA PRADESH


MATERIAL REQUIRED FOR R.C.C.P.

1. Cement

2. Aggregate

3. Water

4. Sealants


CEMENT FOR R.C.C.P.

1. As per IS 8112 Ordinary Portland Cement 43 Grade

2. As per IS 1489 Ordinary Portland Pozzolana Cement


PACKAGE NO.MP-0511 PILOT PROJECTNIPANIYA TO KANERA (KAROND KHURD)

CHECKING THE MATERIALS (CEMENT & AGGREGATES) BY S.T.A. FOR R.C.C.P.


AGGREGATES GRADATIONS FOR R.C.C.P

Sieve Designation Percentage Passing the Sieve by Weight

Achieved at site

26.50mm 100 100

19.00mm 80-100 92

9.50mm 55-75 77

4.75mm 35-60 50

600micron 10-35 21

75micron 0-5 4


WATER CONTENT FOR R.C.C.P.

1. 0.365 (W/C Ratio)

2. The water content is 6.75% of weight of cement and aggregates (Fine and coarse)

3. Zero Slump should be observed.


SEALANTS FOR R.C.C.P.

- Rubberized/Polymerized Bitumen.

- Sealants shall be filled with hot poured sealing compound as per clause 1501.22 of these specifications and in accordance with IS: 1834.


FORM WORK REQUIRED FOR R.C.C.P.

All side forms shall be of mild steel channel sections of depth equal to the thickness the pavement. The forms shall be held firmly in place by stakes driven to the ground. All forms shall be cleaned and oiled each time they are used. The forms shall be jointed neatly and set with exactness to the required grade and alignment.



CHECKING THE WORKABILITY OF FRESH CONCRETE (SLUMP TEST) FOR R.C.C.P.



CHECKING THE WORKABILITY OF FRESH CONCRETE (ZERO SLUMP) FOR R.C.C.P.



PREPARING THE MOULD FOR CHECKING THE STREANGTH OF CONCRETE



SHOWING THE FORM WORK FOR R.C.C.P


MACHINERY REQUIRED FOR R.C.C.P.

1. Needle vibrator

2. Plate vibrator

3. Screed vibrator

4. Mobile Concrete Batching

5. Static roller, Vibratory (Double drum tandem roller), Numatic rollers.

6. Concrete contraction joint cutter (Saw)



LAYING THE CONCRETE BY MOBILE CONCRETE BATCHING FOR R.C.C.P.



SHOWING THE MOBILE CONCRETE BATCHING FOR R.C.C.P.



SHOWING THE SCREED VIBRATOR FOR COMPACTION


ROLLING SEQUENCE FOR R.C.C.P.S. No

Type of Roller No. of Static

passes

No. of vibrating passes

Remarks

1. Double drum tandem roller

2Nil

1-2

Nil4-6

Nil

Breakdown rollingVibratory rolling with amplitude 0.8-0.4 mmSmoothening

2. Single front drum steel roller with rear tyres of rubber

1Nil

1-2

Nil4-5

Nil

Breakdown rollingVibratory rolling with amplitude descendingFrom 0.8 to 0.4mm Smoothening



SHOWING THE COMPACTION BY STATIC ROLLER FOR R.C.C.P.



SHOWING THE COMPACTION BY VIBRATORY ROLLER

FOR R.C.C.P.



SHOWING THE COMPACTION BY STATIC ROLLER FOR R.C.C.P.



SHOWING THE COMPATION BY SCREED VIBRATOR & VIBRATORY ROLLER

FOR R.C.C.P.


CONTRACTION JOINT FOR R.C.C.P.

1. No longitudinal joint was provided.

2. Transverse contraction joints at 5m centre to centre was provided after 18-24 Hrs. of laying.


CURING FOR R.C.C.P.

1. Curing start within one hour to two hours, after laying by covering the R.C.C.P. with wet hessian in two-three layers for first 24 hours.

2. After the first day’s curing, small earthen rectangles about 50mm high transversely and longitudinally shall be made and shall be filled with water for at least 14 more days.



CURRING BY SPRINKLING OF WATER WITH WET HESSIAN FOR R.C.C.P.



CURRING BY SPRINKLING OF WATER WITH WET HESSIAN FOR R.C.C.P.


METHODOLOGY FOR R.C.C.P.

1. Laid Trial Length of 10-10m reaches (total 40m Length) for different Ingredients and Zero Slump Concrete, rolled with Vibratory Roller of 80 to 100 kN static weight. The trial length as per rolling sequence are taken as the observation/results in the following Reaches:-

Reach-1

Reach-2

Reach-3

Reach-4


RESULT OF TRIAL LENGTH- REACH-1Ingredients

Trial Length (Table No.-1)

Reach-1

Cement Used OPC- 330 Kg.

Fine Aggregate 692 Kg.

Coarse Aggregate 1284 Kg.

Water 116 Litre

W/C Ratio 0.35

Water Content 5 % weight of Cement and Aggregates

Slump Zero

Observation Difficulties in operating Screed Vibrator due to harsh Concrete. Hence proper Camber could not be maintained and honey combing is observed in several places. Further non availability of OPC and Flyash, it was decided to make trial length using PPC with increased cement and water content

Average Strength of Cylindrical Core (After 7 Days)

210.0 Kg/sqcm

Target Strength 180.2 Kg/sqcm

Result/Remark Rejected


IngredientsTrial Length (Table No.-1)

Reach-2

Cement Used PPC- 360 Kg.



Water 135 Litre

W/C Ratio 0.375

Water Content 5.97 % weight of Cement and Aggregates

Slump Zero

Observation Smooth Surface could not be obtained, hence it was decided to increase the water content with same cement content.

Average Strength of Cylinderical Core (After 7 Days)

181.8 Kg/sqcm


Result/Remark Pass**But it failed after 28 days strength (refer Table-2)

RESULT OF TRIAL LENGTH- REACH-2



Reach-3




Water 147 Litre

W/C Ratio 0.408


Slump Zero

Observation Water content became high and it was not possible to compact using roller. Therefore it was decided to reduce water content with same cement content.


164.5 Kg/sqcm


Result/Remark Fail




Reach-4




Water 139 Litre

W/C Ratio 0.386


Slump Zero

Observation Compaction using roller and mix was satisfactory, proper profilewas maintained, Hence Trial Length seems to be satisfactory.


190.5 Kg/sqcm


Result/Remark Pass and hence recommended




CYLINDRICAL CORE CUT BY CORE CUTTING MACHINE



CYLINDRICAL CORE FOR TESTING THE CRUSHING STRENGTH


AVERAGE CRUSHING STRENGTH OF CORES AFTER 28 DAYS

Ingredients Location"L"

Location"C1"

Location"C2"

Location"R"

Result

Cement OPC - 330 KgFine Agg. - 692 KgCoarse Agg. - 1284 KgWater - 116 Ltr-5% wt. of Cement & Aggts-Zero Slump

Cylindrical coreDia - 10 cmHeight - 15.1 cmWeight - 2.997 KgDensity - 2526 Kg/CumCrusingStraingth- 286.36 Kg/sqcm


276.81 Kg/sqcm

Trial Length Reach-1 (Table No.-2)




Location"C1"

Location"C2"

Location"R" Result

Cement PPC - 360 KgFine Agg. - 664 KgCoarse Agg. - 1234 KgWater - 135 Ltr-5.97% Wt. of Cement & Aggts-Zero Slump





283.04 Kg/sqcm





Location"C1"

Location"C2"

Location"R"

Result




289.55 Kg/sqcm





Location"C1"

Location"C2"

Location"R"

Remark


Cylindrical coreDia - 10 cmHeight - 15.2 cmWeight - 3.043 KgDensity - 2548 Kg/CumCrusingStraingth - 400.91 Kg/ sqcm




345.23 Kg/sqcm



CRUSHING STRENGTH OF CORES AFTER 28 DAYS (MAIN REACHES)

S. No. Chainage

Weight of Cylindrical

Core

Volume of Core Density Strength

1. 9060 (L) 3078 1194.26 2.57 318.18 Kg/Sq.Cm.

2. 9030 (L) 3064 1202.14 2.55 407.28 Kg/Sq.Cm.

3. 9010 (R) 3113 1202.14 2.59 407.28 Kg/Sq.Cm.

4. 8990 (C) 3037 1194.26 2.54 470.91 Kg/Sq.Cm.

5. 8975 (R) 3010 1217.83 2.47 235.45 Kg/Sq.Cm.

6. 8960 (R) 3050 1194.26 2.55 381.82 Kg/Sq.Cm.

Average Strength = 370.15 Kg/Sq.Cm.


DO’S AND DON’TS FOR R.C.C.P.S. No

Do’s Don’ts

1. Determine optimum moisture content requirement after making field trial construction.

Do not lay sub-base on a sub-grade softened by rain.

2. Do ensure uniform spreading of concrete to ensure uniform density, proper compaction and achievement of designed thickness.

Do not allow normal working till the trial length has been approved.

3. Do taper concrete in half a metre length at the end of day’s work. Before commencement of work on the next day, this half metre width should be cut straight and fresh concrete abutting the old concrete is laid.

Do not provide any vertical step between the adjacent side forms greater than 3mm.


DO’S AND DON’TS FOR R.C.C.P.S. No

Do’s Don’ts

4. Commence rolling from lower edges to center/super-elevated edges.

Do not make up depressions, while placing RCCP, by depositing fine material.

5. Ensure sufficiency and accuracy of material, plant and equipment and methods of construction by laying a trial length.

Do not use flyash as replacement of cement if Portland Pozzolana flyash based or any other blended cement is used.

6. Use flexible synthetic or jute rope to avoid infiltration of foreign particles/dust in empty joints.

Do not allow any traffic, including construction vehicles on the finished surface of concrete pavement till the joints are permanently sealed.



CHECKING OF R.C.C.P. BY DIRECTOR, NRRDA



CHECKING OF R.C.C.P. BY DIRECTOR, NRRDA


CONCLUSION1. The work of R.C.C.P. done by us is economical in comparison

to traditional concrete.

2. The final strength of concrete in R.C.C.P. is on the higher side in comparison to traditional concrete work. (In use of nominal mix of M-20 we obtained the strength of design mix M-40).

3. The cement consumption in this case is reduced, per cum concrete of 330 Kg whereas with traditional concrete M-30, the consumption of cement is 440 Kg.

4. Speedily/Economical construction of R.C.C.P. due to ‘not required expansion joints’.

5. Thus the work of R.C.C.P. becomes less cumbersome in operation and less time consuming as well.



Documents

ROLLER COMPACTED CONCRETE PAVEMENTpmgsy.nic.in/rcc.pdf · m.p. rural road development authority, project implementaion unit, bhopal roller compacted concrete pavement pilot project