Tennessee Concrete Pavement and Cement
Based Solutions Conference
Nashville TN
February 1,2013
Roller -Compacted Concrete Pavements
Design and Construction
Stan Bland, PE
Pavement Applications Director Carolinas/Virginia
Portland Cement Association, Southeast Region
Definition
Roller
Roller-Compacted
Compacted Concrete (RCC) is a no
no-slump
slump concrete
that is compacted by vibratory rollers.
Zero slump (consistency of dense graded aggregate)
No forms
No reinforcing steel
No finishing
Consolidated with vibratory rollers
Concrete pavement placed in a different way!
Un-compacted RCC
S f
Surface
A
Appearance
Not as smooth as
conventional
concrete
Important to
recognize
g
difference
Similar appearance
to asphalt only light
grey instead of black
Surface Texture
Engineering Properties
Compressive
C
i strength
t gth (fc)
4,000 to 10,000 psi
Flexural strength (MR)
500 to 1,000
,
p
psi
MR = C(fc)1/2 where C = 9 (up to 11)
Modulus
M d l off elasticity
l ti it
3,000,000 to 5,500,000 psi
E = CE(fc)1/2 where CE = 57,000 (up to
67,000)
Applications
pp
Saluda Dam - Columbia, South Carolina
Dam Crest
D
C
Raise
R i
Alabama Power - Rattlesnake Hollow
Crest of Existing earthen dam raised by 30 feet.
RCC used to provide vertical face due to width restraints.
Log Sort Yards
Vancouver Island, BC, 1978
Military Facilities
Ft. Carsons, CO, 2008
Ft. Lewis, WA ,1986
Ft. Drum, NY, 1990
Intermodal Facilities
Central Station
Station, Detroit
Detroit, MI
Burlington Northern, Denver, CO
CN Intermodal Yard, Calgary
RCC decreased
t k wait
truck
it time
ti
from
f
8 to 2 hours
Unsurfaced aggregate
is difficult to maneuver
and presents safety
hazard
Port Terminals
Norfolk International
Terminal, VA, 2006
Port of Houston, TX, 2007
Distribution Centers
18 acre distribution
center in Austin, TX
10 years after construction
GM Saturn Plant
Spring Hill, Tennessee
Honda Plant
Lincoln, Alabama
M
Mercedes-Benz
d B
Pl
Plant
Vance, Alabama
Streets & Interchanges
Intersection replacement
Calgary, AB
Residential street
Columbus, OH
Columbus, Ohio Area
Hi h
Highway
Sh
Shoulders
ld
I-285 Highway
Atlanta, GA
Construction
Subbase/Subgrade Preparation
Same requirements as
conventional concrete.
Must be stiff to provide
full compaction.
Stable subgrade.
Non-pumping subbase.
Moisten subbase prior to
RCC placement.
Mixing Plants
Generally three types of
available mixing operations:
1. Dry Batch Plant
2. Rotary Drum Mixing Plant
3. Continuous Flow Pugmill
Mixing Plants
Rotary Drum Plant
Available at some locations.
Mobilization issues.
Capacity reduced due to low water
content of mixture.
Continuous Mix Pug Mill
High-volume
applications
E ll t mixing
Excellent
i i
efficiency for dry
materials
250 to 900+ tons/hr
Mobile, erected on site
Mobilization costs
Transporting
RCC Pavement Placement
Placing
Layer Thickness
4 in. Minimum Thickness.
9 10 in.
in Maximum Thickness in a single lift
lift.
Timing Sequence
Adjacent lanes placed within 60 minutes for fresh
fresh joint
joint
Multiple lifts placed within 60 minutes for fresh joint
Production should match paver capacity
Continuous forward motion for best smoothness
Placing Equipment
High density pavers
Vibrating screed
Dual tamping bars and or
pressure bars
High initial density, 90-95%
Reduces subsequent
compaction
High-volume placement
(1,000 to 2,000 cubic yards
per shift)
Designed for harsh mixes
Smoothest RCC surface
Roller Compaction
(rubber-coated drum)
Compaction-Final Density
Final density is critical for
strength and durability
C
Compacted
t d to
t 98% Modified
M difi d
Proctor
Dual Steel Drum Roller
Combination Roller
Rubber coated steel drum
roller
Compaction Very Important
Transverse Joints
Curing
Extremely important; Ensures surface durability
Low moisture content in RCC dictates moisture
retention.
Three methods:
Moist Cure
Concrete Curing Compound
Asphalt Emulsion
Concrete Curing Compound
White-pigmented
concrete curing
compounds
Apply 1 to 1.5 times the
normal application rate
Bituminous Curing Compound
Excellent moisture barrier
Clean surface if needed
Common compounds:
SS-1, RC-250, MC-250
Moisten surface
Apply at 0.15
0 15 to0.30
to0 30 gal/sy
Good for asphalt cap
Quality Control
OPENING TO TRAFFIC
Accessibility To Apartment Complex was a Critical
Element For This Project
A
Access
Was
W P
Provided
id d Di
Directly
tl Behind
B hi d The
Th ABG
Paver-Prior To Roller Compaction
SCDOT Specifications
Traffic:
Protect the RCC from vehicular traffic during the
curing period. Completed portions of the RCC
pavement may be opened to automotive and light
truck traffic as soon as the strength is sufficient to
preventt damage
d
to
t the
th RCC.
RCC Th
The pavementt may
be opened to unrestricted traffic after 4 days.
Why are we using it?
(Andy Johnson SCDOT State Pavement Engineer)
Most or all of pavement structure can be placed in
one lift.
lift
Does not require the curing time or adjacent lane
encroachment
e
c oac e t of
o traditional
t ad t o a PCC.
CC
Can handle heavy loads and high traffic volumes.
Overall structure cost is very competitive with other
pavement types.
Should be able to bridge poor subgrades effectively,
effectively
if you can get it installed.
RCC Projects in South Carolina
SC Projects
Powell Pond Rd,
Rd Aiken County (Demo.
(Demo Project)
SC 5, York County
US 78,
8, C
Charleston
a esto County
Cou ty
New State Road, Lexington County
Greystone Boulevard, Richland County
S. Beltline Boulevard, Richland County
Richland Street (US78), Aiken County
SC 9, Horry County
S-11-171, Cherokee County
I 385 Shoulders
I-385
Shoulders, Laurens County
I-385 Shoulders, Greenville County
Projects in SC
Rt 21 Alb
Albright
i ht R
Road
d
Rt 72 By Pass
R
Rock
k Hill SC
Chester SC
Rt 72 Bypass Chester SC
Constructed
C
t t d in
i September
S t b 2012
Milled 10 inches off of asphalt pavement
Placed 8 inch RCC
Overlay
O l with
i h 2 inches
i h A
Asphalt
h l C
Concrete
Surface Course
72 By Pass
Chester SC
Powell Pond Road
(S-2-2304) Aiken County
(S-2-2304),
County, SC
Ri hl d A
Richland
Avenue (US 78)
78), Aiken,
Aik
SC
The Morgan Co
Greenville Co. SC
Morgan Co
Greenville Co. SC
I-385 RCC Shoulder
Benefits of RCC Pavements
Economical (both initial and life-cycle costs)
High load carrying ability
Eliminates rutting
Excellent overall durability
Simple, fast construction
No forms or finishing
R ll Compacted
Roller
C
t d Concrete
C
t
Questions ???
Dams
D
Intermodal Facilities
Military Bases
Port Terminals
Interstate Shoulders
Auto
A t Industry
I d t Plants
Pl t
Streets and Local Rds
State Highway System
Nuclear Power Plants
Logging Yards
