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Roller-Compacted Concrete Pavements
Wayne S. Adaska, P.E. Christopher Tull, PE LEED APPortland Cement Association CRT Concrete Consulting, LLC
■ Introduction
■ Mixture Design
■ Thickness Design
■ Construction
■ Ready Mixed Producer Approach
■ Case Studies
Presentation Outline
RCC Guide
■ Introduction
■ Applications
■ Properties
■ Mixture Proportioning
■ Structural Design
■ Production
■ Construction
■ Troubleshooting
www.cement.org/bookstorePCA Booth Number S-12501
SN298
Definition
“Roller-Compacted Concrete (RCC) is a no-slump concrete that is compacted by vibratory rollers.”
■ Zero slump (consistency of dense graded damp gravel)
■ No forms or finishing
■ No reinforcing steel
■ High production
■ Pavers or earth moving equipment
■ Consolidated with vibratory rollers
Concrete placed in a different way!
Multiple Personalities
Concrete
• rigid pvmt
Soils
• Proctor test
• density test
Asphalt
• paver
• rollers
Roller-Compacted Concrete
Benefits of RCC Pavements
■ Fast construction
■ Economical
■ Early load carrying capacity
■ Supports heavy loads
■ Low maintenance
■ Durable
■ Light surface reduces lighting requirements and Urban Heat Island effects
■ Originally used for heavy-duty pavements
■ Growth has accelerated in last seven years
■ Increase in private & non military public use
■ Emergence of asphalt contractors placing RCC
RCC – Experiencing a Revival
Asphalt Prices Have Soared
Base Year: 2002 = 100Source: Bureau of Labor StatisticsLast four months of data are preliminary
Applications
■ Ports, intermodal yards and military hard stands
■ Warehouse facilities
■ Parking areas
■ Maintenance & storage yards
■ Airport service areas
■ Arterial roads
■ Highway shoulders
■ Local streets & intersections
Parking Areas
Honda plant, AL, 2001
207 acresSaturn plant, TN, 1988
134 acres
Parking Areas
Sustainable Contributions■ Reduced export/import/fuel use
■ Less mined and processed materials
■ Reduced excavation
■ Faster construction
■ Cooler pavement
■ Used in-situ materials
■ Less damage to area roads
Subgrade
RCC
Soil-Cement Base
6”-8”
6”12”Crushed
Stone Base
Subgrade
4” Asphalt
Design/Bid Section
As Constructed
BMW, SC, 2009
50 acres
Parking AreasTrailer Employee
Truck
Ohio Turnpike Service Plaza, 2010
30 acres
Project Considerations
■ Project size
■ Site geometry
■ Loading characteristics
■ End use
■ Client expectations
Surface Appearance
■ Not as smooth as PCC
■ Similar to HMA binder course
■ Important to recognize
difference
Mixture Design
Mixture Design
■ Dry enough to support vibratory roller
■ Wet enough to permit adequate distribution of paste
Consistency
Mixture Design
■ Modifications needed in no-slump conventional concrete mixture procedures (ACI 211.3R) because RCC is:
▪ Dryer than zero slump
▪ Not air-entrained
▪ Lower cement content
▪ Higher fines content (up to 8% of non plastic fines)
▪ Nominal max. size aggregate 1/2 to 3/4 in.
Conventional Concrete & RCCPercent by
Volume
Conventional PCC
11 16 6 26 41C.M. Water Air Fine Agg. Coarse Agg.
143 pcf
Roller Compacted Concrete
10 13 1.5 35 40.5C.M. Water Air Fine Agg. Coarse Agg.
153 pcf
Proportioning Methods
■ Several methods available:
■ Concrete consistency method
■ Soil suspension method
■ Optimal paste volume method
■ Soil compaction method
Soil Compaction Method
■ Most common method used in the U.S. for RCC paving mixtures
■ Testing equipment readily available at construction materials laboratories
■ Three major steps
1) Select aggregate blend with minimal voids
2) Determine optimum moisture content and maximum density (modified Proctor test)
3) Determine cementitious content
Step 1: Selection of Aggregate Blend
Step 1: Selection of Aggregate Blend
0
10
20
30
40
50
60
70
80
90
100P
erc
en
t P
asin
g
Sieve Number
RCCP Gradation Band
0.45 Power, 3/4" MS Suggested Lower Limit Suggested Upper Limit
#200#100 #4#16 3/8" 1/2" 3/4" 1"
#50#30 #8
Size NumberPercent Passing
1-in(25 mm)
100
3/4-in (19mm)
90-100
1/2-in (12.5 mm)
70-90
3/8-in(9.5 mm)
60-85
No. 4(4.75 mm)
40-65
No. 16 (1.18 mm)
20-40
No. 100(150 m)
6-18
No. 200(75 m)
2-8
Suggested Blend Gradation
PCA suggested limits
0.45 Power curve
Step 2: Determine Opt. Moisture Content & Maximum Density▪ Select a mid-range cement content (e.g. 12% or
450 pcy)
▪ Perform a modified Proctor test (ASTM D1557)
▪ Construct moisture-density relationship curve
▪ Determine Optimum Moisture Content and Maximum Dry Density
Moisture-Density Relationship
140
141
142
143
144
2% 3% 4% 5% 6% 7% 8%
Dry
De
nsit
y (
lb/
cf)
Moisture Content
Maximum dry density
Optimum moisture
Step 3: Determine Cementitious Content
■ Make and test compressive strength cylinders ■Maintain percent optimum moisture content (use OMC
determined in Step 2)
■Use varying cement content, e.g., 10%, 12%, & 14%
■Mold 3 cylinders at each cement content (ASTM C1435)
■ Select cement content which yields appropriate strength
Strength Testing
Fabricating cylinderswith vibrating hammer
(ASTM C1435)
3000
3500
4000
4500
5000
5500
6000
6500
7000
9 10 11 12 13 14 15
Co
mp
ress
ive
stre
ng
th (
psi
)
Cementitious content (%)
12.7%
Step 3: Determine Cementitious Content
fc required = f’c + overdesign margin of safety
fc
Freeze-Thaw Durability
■ Field performance very good, although not air entrained (PCA publication on Long-Term Performance, RP366)
■ Minor surface paste (1/16”) erodes, then stabilizes
■ RCC results variable under ASTM C666 (F-T) and C672 (Deicer scaling)
■ Conventional concrete tests appear to be too severe based on actual experience
■ Durability tests used for concrete masonry units (ASTM C1262) and precast paving units (ASTM C936) possibly more appropriate
Freeze-Thaw Durability
Thickness Design
Thickness Design of RCC Pavements
■ Follows rigid pavement design methods
■ Plain, undoweled, unreinforced concrete pavement
■ Pavement thickness is a function of:
▪ Design life (load repetitions)
▪ Type of vehicle loading
▪ Engineering properties
▪ Base and subgrade characteristics
Typical Engineering Properties
■ Compressive Strength (f’c)
▪ 4,000 to 6,500 psi
■ Flexural Strength (MR)
▪ 500 to 1,000 psi
▪ MR = C (f’c)1/2 where C ranges from 8 to 12
■ Modulus of Elasticity (E)
▪ 3.5 to 6 million psi
▪ E = CE (f’c)1/2 where CE ranges from 57,000 to
67,000
Design Considerations
■ Structural behavior similar to unreinforced, undoweled conventional concrete pavements
■ Reduced shrinkage as compared to PCC
■ Monolithic slab action for multi-layer construction
■ Load transfer across joints/cracks
■ Thickness
■ 4-inch minimum lift
■ 10-inch maximum single lift
Thickness Design Procedures
■ Heavy duty pavements (loaders, haulers, tanks)
■ PCA design procedure (RCC-PAVE)
■ U.S. Army Corps of Engineers procedure
■ Mixed roadway vehicle traffic (cars, trucks)
■ ACI 330 and ACI 325
■ ACPA StreetPave*
■ AASHTO 1993 (WinPas)*
*When using these programs, increase reliability by 5%
PCA Design Procedure
■ Subgrade support (modulus of subgrade reaction, k)
■ Vehicle characteristics
■ Wheel loads
■ Wheel spacing
■ Tire characteristics (contact area, tire inflation pressure)
■ Number of load repetitions during design life
■ RCC flexural strength, ƒs
■ RCC modulus of elasticity, E
Design Example – PCA Method(From Guide for Roller-Compacted Concrete Pavements)
■ Determine the required RCC
thickness given the following:■ Straddle carrier
■ Axle load = 60,000 lbs
■ Tire inflation pressure = 100 psi
■ k = 100 psi/in.
■ Flexural strength, ƒs = 650 psi
■ E = 4,000,000 psi
■ Load repetitions = 30 per day
■ Design life = 20 yearsSingle wheel
loading
Solution for Design Example
■ For the straddle carrier shown, use single wheel design method
■ Wheel load, P = axle load/2 = 60,000/2 = 30,000 lbs
■ Tire contact area = P/tire pressure
= 30,000/100 = 300 sq in
■ Total design repetitions:■ 20 yr x 365 days/yr x 30 reps/day = 219,000 total reps
■ Determine stress ratio (SR) from Table 5.1 of the RCC Guide:
219,000X
Solution for Design Example
(X – 0.43)/(0.44 – 0.43) = (219,000 – 280,000)/(210,000 – 280,000)
X = 0.438
■ Allowable stress, σ = ƒs×SR
= 650×0.438 = 285 psi
■ Allowable stress per 1000-lb load
= σ / (P/1000) = 285/30
= 9.5 psi/kip
Solution for Design Example
11.5 in.
Determine thickness from Figure 5-3
■ Enter chart (Figure 5-3 in RCC Guide) with tire contact area = 300 sq in.; k = 100 pci; and allowable stress = 9.5 psi/kip
■ Slab thickness of 11.5 in. is required
RCC-PAVE Computer Program
■ Pavement evaluation or thickness design
■ Interior or edge loading
■ Standard vehicle and user defined loading options
■ Developed for heavy-duty pavements with less than 700,000 total load repetitions
■ PCA RCC-PAVE Program available at www.cement.org/bookstore
MC043
Construction
Construction Procedures
■ Test section
■ Subgrade preparation
■ Mixing process
■ Transporting
■ Placing
■ Compacting
■ Curing
Test Sections
■ Train contractor and testing personnel
■ Demonstrate workability and
appearance of mix
■ Demonstrate equipment capabilities
■ Demonstrate construction details
■ Joints, bonding, compaction, etc.
■ Develop rolling requirements/pattern
■ Test RCC and develop correlation
factors for density and f’c vs. MR
Subgrade Preparation
■ Must be firm
■ Check with proof roller or compact to 95% min. density
■ Replace unsuitable materials
■ Shape to proper lines and grades
Continuous Pugmill
■ High-volume applications
■ 125 to 250 + cy/hr
■ Excellent mixing efficiency
■ Mobile, erected on site
Central Concrete Batch Plant
■ Highly accurate proportioning
■ Local availability
■ Smaller output capacity
■ Longer mix times than conventional concrete
■ Possibly more cleaning
■ Dedicated production
Dry Concrete Batch Plant
■ Highest local availability
■ Very good for small jobs
■ 2-step process■ Feeds transit mixers■ Discharge into dumps
■ Mix 60 -70% capacity
■ Low production
■ Segregation concern
Dry Concrete Batch Plant
■ Supplementary mixer can aid in thorough mixing and plant throughput.
Transporting
■ Rear dump trucks normally used
■ Minimize transport time
■ Covers required for long hauls, or hot/windy conditions
Placing
■ Production should match paver capacity
■ Layer Thickness■ 4” minimum thickness
■ 9” – 10” maximum thickness
■ Timing Sequence■ Limited time (generally 60 minutes max.) for
placement of adjacent lanes to maintain “fresh joint”
■ Multiple lifts placed within 60 minutes for “fresh joint”
Placing Equipment
Conventional asphalt pavers
■ Provide some initial density (80-85%)
■ Thicknesses < 6 in.
■ Relatively smooth surface
■ May require some equipment modification
Placing Equipment
High density pavers Vibrating tamping
screed
High initial density, 90-95%
Less roll-down
Thicknesses < 10 in.
High-volume placement (1K to 2K cubic yards per shift)
Compaction
■ Proper compaction is critical for strength and durability
■ Compact to 98% Modified Proctor (ASTM D1557)
■ Vibratory roller
■ Pneumatic tire or rubber coated steel drum to smooth surface
Compaction Very Important
Edge Compaction
Compaction shoe
Edges Critical to Performance
■ Compaction more difficult
■ Segregation more likely
■ Try to minimize number of cold joints
■ Care needed to match grade from cold to fresh joint
Fresh Joint
Running Cold Joints
Curing
■ EXTREMELY IMPORTANT
■ Water or concrete curing compound
■ Application rate depends on surface texture
More Information
www.cement.org/pavements
RCC from a Ready
Mix Producer’s
Perspective
Water Content
• Different!
• Water cement ratio is not important or
designed to.
• Water content determined by the required
compaction.
• Seems like a small window, but it can be
done.
Soil Compaction Method
• Determine moisture content
– Construct moisture/density curve
– Modified proctor ASTM D1557
– Assume a median cement content (e.g. 15
percent)
130
135
140
145
150
155
160
3.0% 4.0% 5.0% 6.0% 7.0%
Den
sity
(p
cf)
Moisture Content (%)
Moisture Density Relationship
Dry Density Wet Density
Modified Proctor
How Much Water?
• Add Total Dry Weights
– Cement
– Supplementary cementitous
– Dry fine aggregate
– Dry coarse aggregate
• Multiply by the optimal moisture content
Water Tolerance
• Is it too tight?
• It is tight, but not too tight.
• Compaction in the field must be 98% of the
optimal wet density.
• Too dry or too wet, it is not physically
possible to get the required compaction.
130
135
140
145
150
155
160
3.0% 4.0% 5.0% 6.0% 7.0%
Den
sity
(p
cf)
Moisture Content (%)
Moisture Density Relationship
Dry Density Wet Density
Modified Proctor
Moisture
Window
Can We Do It?
Low End Optimal High End
pounds/cy 47 63 87
Gallons/cy 5.6 7.6 10.4
+/- 2 gallons (ish)/cy
RCC VIA
READY MIX
PROJECTS
UNION COUNTY
Clifton Rd
Union County
Wanda Hartman &
Southeast Cement
Association RCC Seminar
She believed it could be
done with local equipment
Teamed with IMI & Union
County Crews
Union County
• Project was completed
quickly.
• We did not have a proctor
• We did make some cylinders
• Wanda calls it “White Cold
Patch”
Useful Information… But?
Can we obtain enough
compaction through a
conventional county owned
asphalt paver and roller?
HENRY COUNTY
Access Rd
Henry County
• Perform a test pour at
Buster’s landfill access road
• Do a full scale analysis of
the system
Batching
• Buster’s older plant in New Castle
• Placed into ready mix truck
• Transported into Dump trucks
READY MIX TO DUMP
TRUCK
DUMP TRUCK TO JOBSITE
CHECK DEPTH OUT OF THE
PAVER
DENSITY OUT OF PAVER
CALIBRATED TO PROCTOR
ROLL WITHOUT AND WITH
VIBRATOR ON
DENSITY AFTER ROLLING
Lift
(in)
Wet
Density
(pcf)
Dry
Density
(pcf)
Moisture
(%)
Proctor
(%)
Roller
(y/n)
# Passes
w/o
Vibrator
# Passes
w/
Vibrator
6 117.8 109.7 7.4 74 No 0 0
9 116.1 109.4 6.2 74 No 0 0
6 144.9 136.5 6.2 92 Yes 1 0
6 148.8 138.8 7.3 94 Yes 2 0
8 147.4 137.8 7 93 yes 2 0
8 161.9 151.3 7 102 Yes 2 1
First Run
Lift
(in)
Wet
Density
(pcf)
Dry
Density
(pcf)
Moisture
(%)
Proctor
(%)
Roller
(y/n)
# Passes
w/o
Vibrator
# Passes
w/
Vibrator
6 118.7 111.9 6 76 No 0 0
9 114.4 108.6 5.3 73 No 0 0
6 143.1 135.2 5.8 91 Yes 0 1
9 138.9 131.6 5.5 89 Yes 0 1
9 147.3 138.9 6 94 Yes 0 2
6 153.2 145.2 5.5 98 Yes 0 2
6* 149.0 140.1 6.3 95 Yes 0 2
* Tested at joint
Second Run
Made Cylinders for Compressive Slit Tensile
Comparison
COMPRESSIVE STRENGTH
SPLIT TENSILE
SPLIT TENSILE
GOOD RESULTS
Testing Data(56 day: 28 dry, 28 fog room)
Compressive Load
(lbs)
Stress
(psi)
Sample 1 251,500 8,900
Sample 2 231,380 8,180
Average 241,440 8,540
Split Tensile Load
(lbs)
Stress
(psi)
Sample 1 86,620 765
Sample 2 90,125 790
Average 88,373 778
Split Tensile = 8.4 *√Compressive
CITY OF INDIANAPOLIS
Coolridge
Rd
DAVIESS
COUNTY
200E from 650S to 675S
Dry Batch
Conventional Paver
Roll Down
Fresh Joint
Rolling Fresh Joint
350N from 450E to 575E
Twin Shaft Mixer on Same Plant
Surface Texture
High Density Paver
Moisture Control
Curing
CONLUSIONS
1. Ready Mix Plants can producer quality
roller compacted concrete
2. County highway asphalt pavers & rollers
can provide enough energy to obtain 98%
of the modified proctor
3. High density pavers have a better surface
appearance
CONLUSIONS5. Small coarse aggregate size make for
tighter surface finish
6. Exposed RCC probably not aesthetically
acceptable in a retain environment: asphalt
surface
7. PCA is providing guidance on how much
“credit” to give the asphalt in a composite
system: not much
PCA Guidance
Don’t Break the Rules…
An Amazing Product
Time for A Short Quiz
QUESTIONS?