recent advances in design & construction of...
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- 1 -
Recent Advances in Design amp Construction of RCCPRCC4PA Camp Hill PA
February 26 2015
- 2 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 3 -
DEFINITION
ldquoRoller-Compacted Concrete (RCC) is a no-slump concrete that is
placed with asphalt type pavers and compacted by vibratory rollersrdquo
Zero slump (consistency of damp dense gravel)
No forms or finishing
No reinforcing steel
High production
Asphalt paving equipment
Consolidated with vibratory rollers
Concrete placed in a different way
MULTIPLE CHARACTERISTICS
Concrete
bull rigid pavement
bull strength tests
Soils
bull mix design
bull density test
Asphalt
bull paver
bull rollers
Roller-Compacted
Concrete
APPLICATIONS
Ports intermodal yards and military
hard stands
Warehouse facilities
Parking areas
Maintenance amp storage yards
Airport service areas
Arterial roads
Highway shoulders
Local streets amp intersections
Pothole patches
RCC ndash EXPERIENCING A RENEWAL
Originally used for heavy-duty pavements
Growth has accelerated in last decade
Increase in private amp public road use
Emergence of asphalt contractors placing RCC
000
050
100
150
200
250
-
2
4
6
8
10
12
14
16
18
20
Yearly R
CC
C
um
ula
tive
RC
C
(Mill
ion
SY
)
Yearly Sq Yds
Cumulative Sq Yds
(Millio
n S
Y)
1975 - 1999 2000-2010 2011-2013
of Projects 71 99 172
SY 2999771 8933250 4993296
Concrete PPI
Asphalt PPI
Paving Material PPI Price Comparisons1996 = 100
Source Bureau of Labor Statistics Producer Price Indices
VOLATILITY OF ASPHALT PRICES
- 8 -
RCC MAKES STRANGE BEDFELLOWS
- 9 -
BENEFITS OF ROLLER-COMPACTED CONCRETE
Fast construction
Economical
Early load carrying capacity
Supports heavy loads
Low maintenance
Durable
Light surface reduces lighting requirements
and Urban Heat Island effects
PROJECT CONSIDERATIONS
Project size
Site geometry
End use
Client expectations
- 11 -
SURFACE APPEARANCE
Asphalt RCCRCC Conventional
Concrete
Diamond
Ground
RCC
Diamond
Ground
Conventional
Concrete
frac34rdquo Max Sizefrac12rdquo Max Size
- 12 -
TECHNOLOGIES TO IMPROVE SURFACE APPEARANCE
bull Colloidal Silica
bull Reacts with cement to increase paste
bull Improves surface appearance
bull Reduces surface dusting
bull Improves surface durability
RCC
Surface
Pro
- 13 -
SURFACE APPEARANCE
Maryhill Catholic Cemetery Niles IL
Untreated
Treated
- 14 -
SURFACE APPEARANCE
Untreated
Treated
- 15 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 16 -
MIXTURE PROPORTIONING PHILOSOPHIES
- 17 -
RCC MIXTURE DESIGN
Modifications needed in typical no-slump concrete
mixture procedures (ACI 2113R) because RCC is
Dryer than zero slump
Not air-entrained
Lower cementitious content
Higher fines content
Nominal max size aggregate 12 to 34 in
- 18 -
CONVENTIONAL CONCRETE amp RCC
Percent by
Volume
Conventional Air-Entrained PCC
12 16 6 22 44
CM Water Air Fine Agg Coarse Agg
144 pcf
Roller Compacted Concrete
10 14 15 36 385CM Water Air Fine Agg Coarse Agg
153 pcf
- 19 -
SOIL COMPACTION METHOD
Most common method used in the US 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
(ASTM D1557)
3) Determine cementitious content
- 20 -
STEP 1 AGGREGATE SELECTION
Aggregate selection very important
85 of mix by volume
Responsible for mix workability
segregation amp ease of consolidation
Quality of aggregates should meet
ASTM C33
- 21 -
STEP 1 AGGREGATE SELECTION
Nominal Maximum Size Aggregate
ndash Most projects 58rdquo to 34rdquo
ndash As small as 12rdquo for tighter surface and reduced
segregation
ndash 1-12rdquo may be used for non-wearing courses or
where surface appearance is not critical
Plasticity Index (PI) lt 5
Multiple aggregate piles
Consider availability when preparing specs
(during design phase)
- 22 -
STEP 1 AGGREGATE SELECTION
0
10
20
30
40
50
60
70
80
90
100
Pe
rce
nt
Pa
sin
g
Sieve Number
RCCP Gradation Band
045 Power 34 MS Suggested Lower Limit Suggested Upper Limit
200100 416 38 12 34 1
5030 8
Size NumberPercent
Passing
1-in
(25 mm)100
34-in
(19mm)90-100
12-in
(125 mm)70-90
38-in
(95 mm)60-85
No 4
(475 mm)40-65
No 16
(118 mm)20-40
No 100
(150 mm)6-18
No 200
(75 mm)2-8
Suggested Blend
Gradation
PCA suggested
limits
045 Power
curve
- 23 -
Select a mid-range cement content
(eg 12 or 450 pcy)
Perform a modified Proctor test (ASTM
D1557)
Construct moisture-density
relationship curve
Determine Optimum Moisture Content
and Maximum Dry Density
STEP 2 DETERMINE OPTIMUM MC amp MAX DENSITY
Modified Proctor
ASTM D1557
MOISTURE-DENSITY RELATIONSHIP
140
141
142
143
144
2 3 4 5 6 7 8
Dry
De
nsit
y (l
b
cf)
Moisture Content
Maximum density
Optimum moisture
- 26 -
COMPACTION VERY IMPORTANT
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 2 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 3 -
DEFINITION
ldquoRoller-Compacted Concrete (RCC) is a no-slump concrete that is
placed with asphalt type pavers and compacted by vibratory rollersrdquo
Zero slump (consistency of damp dense gravel)
No forms or finishing
No reinforcing steel
High production
Asphalt paving equipment
Consolidated with vibratory rollers
Concrete placed in a different way
MULTIPLE CHARACTERISTICS
Concrete
bull rigid pavement
bull strength tests
Soils
bull mix design
bull density test
Asphalt
bull paver
bull rollers
Roller-Compacted
Concrete
APPLICATIONS
Ports intermodal yards and military
hard stands
Warehouse facilities
Parking areas
Maintenance amp storage yards
Airport service areas
Arterial roads
Highway shoulders
Local streets amp intersections
Pothole patches
RCC ndash EXPERIENCING A RENEWAL
Originally used for heavy-duty pavements
Growth has accelerated in last decade
Increase in private amp public road use
Emergence of asphalt contractors placing RCC
000
050
100
150
200
250
-
2
4
6
8
10
12
14
16
18
20
Yearly R
CC
C
um
ula
tive
RC
C
(Mill
ion
SY
)
Yearly Sq Yds
Cumulative Sq Yds
(Millio
n S
Y)
1975 - 1999 2000-2010 2011-2013
of Projects 71 99 172
SY 2999771 8933250 4993296
Concrete PPI
Asphalt PPI
Paving Material PPI Price Comparisons1996 = 100
Source Bureau of Labor Statistics Producer Price Indices
VOLATILITY OF ASPHALT PRICES
- 8 -
RCC MAKES STRANGE BEDFELLOWS
- 9 -
BENEFITS OF ROLLER-COMPACTED CONCRETE
Fast construction
Economical
Early load carrying capacity
Supports heavy loads
Low maintenance
Durable
Light surface reduces lighting requirements
and Urban Heat Island effects
PROJECT CONSIDERATIONS
Project size
Site geometry
End use
Client expectations
- 11 -
SURFACE APPEARANCE
Asphalt RCCRCC Conventional
Concrete
Diamond
Ground
RCC
Diamond
Ground
Conventional
Concrete
frac34rdquo Max Sizefrac12rdquo Max Size
- 12 -
TECHNOLOGIES TO IMPROVE SURFACE APPEARANCE
bull Colloidal Silica
bull Reacts with cement to increase paste
bull Improves surface appearance
bull Reduces surface dusting
bull Improves surface durability
RCC
Surface
Pro
- 13 -
SURFACE APPEARANCE
Maryhill Catholic Cemetery Niles IL
Untreated
Treated
- 14 -
SURFACE APPEARANCE
Untreated
Treated
- 15 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 16 -
MIXTURE PROPORTIONING PHILOSOPHIES
- 17 -
RCC MIXTURE DESIGN
Modifications needed in typical no-slump concrete
mixture procedures (ACI 2113R) because RCC is
Dryer than zero slump
Not air-entrained
Lower cementitious content
Higher fines content
Nominal max size aggregate 12 to 34 in
- 18 -
CONVENTIONAL CONCRETE amp RCC
Percent by
Volume
Conventional Air-Entrained PCC
12 16 6 22 44
CM Water Air Fine Agg Coarse Agg
144 pcf
Roller Compacted Concrete
10 14 15 36 385CM Water Air Fine Agg Coarse Agg
153 pcf
- 19 -
SOIL COMPACTION METHOD
Most common method used in the US 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
(ASTM D1557)
3) Determine cementitious content
- 20 -
STEP 1 AGGREGATE SELECTION
Aggregate selection very important
85 of mix by volume
Responsible for mix workability
segregation amp ease of consolidation
Quality of aggregates should meet
ASTM C33
- 21 -
STEP 1 AGGREGATE SELECTION
Nominal Maximum Size Aggregate
ndash Most projects 58rdquo to 34rdquo
ndash As small as 12rdquo for tighter surface and reduced
segregation
ndash 1-12rdquo may be used for non-wearing courses or
where surface appearance is not critical
Plasticity Index (PI) lt 5
Multiple aggregate piles
Consider availability when preparing specs
(during design phase)
- 22 -
STEP 1 AGGREGATE SELECTION
0
10
20
30
40
50
60
70
80
90
100
Pe
rce
nt
Pa
sin
g
Sieve Number
RCCP Gradation Band
045 Power 34 MS Suggested Lower Limit Suggested Upper Limit
200100 416 38 12 34 1
5030 8
Size NumberPercent
Passing
1-in
(25 mm)100
34-in
(19mm)90-100
12-in
(125 mm)70-90
38-in
(95 mm)60-85
No 4
(475 mm)40-65
No 16
(118 mm)20-40
No 100
(150 mm)6-18
No 200
(75 mm)2-8
Suggested Blend
Gradation
PCA suggested
limits
045 Power
curve
- 23 -
Select a mid-range cement content
(eg 12 or 450 pcy)
Perform a modified Proctor test (ASTM
D1557)
Construct moisture-density
relationship curve
Determine Optimum Moisture Content
and Maximum Dry Density
STEP 2 DETERMINE OPTIMUM MC amp MAX DENSITY
Modified Proctor
ASTM D1557
MOISTURE-DENSITY RELATIONSHIP
140
141
142
143
144
2 3 4 5 6 7 8
Dry
De
nsit
y (l
b
cf)
Moisture Content
Maximum density
Optimum moisture
- 26 -
COMPACTION VERY IMPORTANT
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 3 -
DEFINITION
ldquoRoller-Compacted Concrete (RCC) is a no-slump concrete that is
placed with asphalt type pavers and compacted by vibratory rollersrdquo
Zero slump (consistency of damp dense gravel)
No forms or finishing
No reinforcing steel
High production
Asphalt paving equipment
Consolidated with vibratory rollers
Concrete placed in a different way
MULTIPLE CHARACTERISTICS
Concrete
bull rigid pavement
bull strength tests
Soils
bull mix design
bull density test
Asphalt
bull paver
bull rollers
Roller-Compacted
Concrete
APPLICATIONS
Ports intermodal yards and military
hard stands
Warehouse facilities
Parking areas
Maintenance amp storage yards
Airport service areas
Arterial roads
Highway shoulders
Local streets amp intersections
Pothole patches
RCC ndash EXPERIENCING A RENEWAL
Originally used for heavy-duty pavements
Growth has accelerated in last decade
Increase in private amp public road use
Emergence of asphalt contractors placing RCC
000
050
100
150
200
250
-
2
4
6
8
10
12
14
16
18
20
Yearly R
CC
C
um
ula
tive
RC
C
(Mill
ion
SY
)
Yearly Sq Yds
Cumulative Sq Yds
(Millio
n S
Y)
1975 - 1999 2000-2010 2011-2013
of Projects 71 99 172
SY 2999771 8933250 4993296
Concrete PPI
Asphalt PPI
Paving Material PPI Price Comparisons1996 = 100
Source Bureau of Labor Statistics Producer Price Indices
VOLATILITY OF ASPHALT PRICES
- 8 -
RCC MAKES STRANGE BEDFELLOWS
- 9 -
BENEFITS OF ROLLER-COMPACTED CONCRETE
Fast construction
Economical
Early load carrying capacity
Supports heavy loads
Low maintenance
Durable
Light surface reduces lighting requirements
and Urban Heat Island effects
PROJECT CONSIDERATIONS
Project size
Site geometry
End use
Client expectations
- 11 -
SURFACE APPEARANCE
Asphalt RCCRCC Conventional
Concrete
Diamond
Ground
RCC
Diamond
Ground
Conventional
Concrete
frac34rdquo Max Sizefrac12rdquo Max Size
- 12 -
TECHNOLOGIES TO IMPROVE SURFACE APPEARANCE
bull Colloidal Silica
bull Reacts with cement to increase paste
bull Improves surface appearance
bull Reduces surface dusting
bull Improves surface durability
RCC
Surface
Pro
- 13 -
SURFACE APPEARANCE
Maryhill Catholic Cemetery Niles IL
Untreated
Treated
- 14 -
SURFACE APPEARANCE
Untreated
Treated
- 15 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 16 -
MIXTURE PROPORTIONING PHILOSOPHIES
- 17 -
RCC MIXTURE DESIGN
Modifications needed in typical no-slump concrete
mixture procedures (ACI 2113R) because RCC is
Dryer than zero slump
Not air-entrained
Lower cementitious content
Higher fines content
Nominal max size aggregate 12 to 34 in
- 18 -
CONVENTIONAL CONCRETE amp RCC
Percent by
Volume
Conventional Air-Entrained PCC
12 16 6 22 44
CM Water Air Fine Agg Coarse Agg
144 pcf
Roller Compacted Concrete
10 14 15 36 385CM Water Air Fine Agg Coarse Agg
153 pcf
- 19 -
SOIL COMPACTION METHOD
Most common method used in the US 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
(ASTM D1557)
3) Determine cementitious content
- 20 -
STEP 1 AGGREGATE SELECTION
Aggregate selection very important
85 of mix by volume
Responsible for mix workability
segregation amp ease of consolidation
Quality of aggregates should meet
ASTM C33
- 21 -
STEP 1 AGGREGATE SELECTION
Nominal Maximum Size Aggregate
ndash Most projects 58rdquo to 34rdquo
ndash As small as 12rdquo for tighter surface and reduced
segregation
ndash 1-12rdquo may be used for non-wearing courses or
where surface appearance is not critical
Plasticity Index (PI) lt 5
Multiple aggregate piles
Consider availability when preparing specs
(during design phase)
- 22 -
STEP 1 AGGREGATE SELECTION
0
10
20
30
40
50
60
70
80
90
100
Pe
rce
nt
Pa
sin
g
Sieve Number
RCCP Gradation Band
045 Power 34 MS Suggested Lower Limit Suggested Upper Limit
200100 416 38 12 34 1
5030 8
Size NumberPercent
Passing
1-in
(25 mm)100
34-in
(19mm)90-100
12-in
(125 mm)70-90
38-in
(95 mm)60-85
No 4
(475 mm)40-65
No 16
(118 mm)20-40
No 100
(150 mm)6-18
No 200
(75 mm)2-8
Suggested Blend
Gradation
PCA suggested
limits
045 Power
curve
- 23 -
Select a mid-range cement content
(eg 12 or 450 pcy)
Perform a modified Proctor test (ASTM
D1557)
Construct moisture-density
relationship curve
Determine Optimum Moisture Content
and Maximum Dry Density
STEP 2 DETERMINE OPTIMUM MC amp MAX DENSITY
Modified Proctor
ASTM D1557
MOISTURE-DENSITY RELATIONSHIP
140
141
142
143
144
2 3 4 5 6 7 8
Dry
De
nsit
y (l
b
cf)
Moisture Content
Maximum density
Optimum moisture
- 26 -
COMPACTION VERY IMPORTANT
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
MULTIPLE CHARACTERISTICS
Concrete
bull rigid pavement
bull strength tests
Soils
bull mix design
bull density test
Asphalt
bull paver
bull rollers
Roller-Compacted
Concrete
APPLICATIONS
Ports intermodal yards and military
hard stands
Warehouse facilities
Parking areas
Maintenance amp storage yards
Airport service areas
Arterial roads
Highway shoulders
Local streets amp intersections
Pothole patches
RCC ndash EXPERIENCING A RENEWAL
Originally used for heavy-duty pavements
Growth has accelerated in last decade
Increase in private amp public road use
Emergence of asphalt contractors placing RCC
000
050
100
150
200
250
-
2
4
6
8
10
12
14
16
18
20
Yearly R
CC
C
um
ula
tive
RC
C
(Mill
ion
SY
)
Yearly Sq Yds
Cumulative Sq Yds
(Millio
n S
Y)
1975 - 1999 2000-2010 2011-2013
of Projects 71 99 172
SY 2999771 8933250 4993296
Concrete PPI
Asphalt PPI
Paving Material PPI Price Comparisons1996 = 100
Source Bureau of Labor Statistics Producer Price Indices
VOLATILITY OF ASPHALT PRICES
- 8 -
RCC MAKES STRANGE BEDFELLOWS
- 9 -
BENEFITS OF ROLLER-COMPACTED CONCRETE
Fast construction
Economical
Early load carrying capacity
Supports heavy loads
Low maintenance
Durable
Light surface reduces lighting requirements
and Urban Heat Island effects
PROJECT CONSIDERATIONS
Project size
Site geometry
End use
Client expectations
- 11 -
SURFACE APPEARANCE
Asphalt RCCRCC Conventional
Concrete
Diamond
Ground
RCC
Diamond
Ground
Conventional
Concrete
frac34rdquo Max Sizefrac12rdquo Max Size
- 12 -
TECHNOLOGIES TO IMPROVE SURFACE APPEARANCE
bull Colloidal Silica
bull Reacts with cement to increase paste
bull Improves surface appearance
bull Reduces surface dusting
bull Improves surface durability
RCC
Surface
Pro
- 13 -
SURFACE APPEARANCE
Maryhill Catholic Cemetery Niles IL
Untreated
Treated
- 14 -
SURFACE APPEARANCE
Untreated
Treated
- 15 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 16 -
MIXTURE PROPORTIONING PHILOSOPHIES
- 17 -
RCC MIXTURE DESIGN
Modifications needed in typical no-slump concrete
mixture procedures (ACI 2113R) because RCC is
Dryer than zero slump
Not air-entrained
Lower cementitious content
Higher fines content
Nominal max size aggregate 12 to 34 in
- 18 -
CONVENTIONAL CONCRETE amp RCC
Percent by
Volume
Conventional Air-Entrained PCC
12 16 6 22 44
CM Water Air Fine Agg Coarse Agg
144 pcf
Roller Compacted Concrete
10 14 15 36 385CM Water Air Fine Agg Coarse Agg
153 pcf
- 19 -
SOIL COMPACTION METHOD
Most common method used in the US 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
(ASTM D1557)
3) Determine cementitious content
- 20 -
STEP 1 AGGREGATE SELECTION
Aggregate selection very important
85 of mix by volume
Responsible for mix workability
segregation amp ease of consolidation
Quality of aggregates should meet
ASTM C33
- 21 -
STEP 1 AGGREGATE SELECTION
Nominal Maximum Size Aggregate
ndash Most projects 58rdquo to 34rdquo
ndash As small as 12rdquo for tighter surface and reduced
segregation
ndash 1-12rdquo may be used for non-wearing courses or
where surface appearance is not critical
Plasticity Index (PI) lt 5
Multiple aggregate piles
Consider availability when preparing specs
(during design phase)
- 22 -
STEP 1 AGGREGATE SELECTION
0
10
20
30
40
50
60
70
80
90
100
Pe
rce
nt
Pa
sin
g
Sieve Number
RCCP Gradation Band
045 Power 34 MS Suggested Lower Limit Suggested Upper Limit
200100 416 38 12 34 1
5030 8
Size NumberPercent
Passing
1-in
(25 mm)100
34-in
(19mm)90-100
12-in
(125 mm)70-90
38-in
(95 mm)60-85
No 4
(475 mm)40-65
No 16
(118 mm)20-40
No 100
(150 mm)6-18
No 200
(75 mm)2-8
Suggested Blend
Gradation
PCA suggested
limits
045 Power
curve
- 23 -
Select a mid-range cement content
(eg 12 or 450 pcy)
Perform a modified Proctor test (ASTM
D1557)
Construct moisture-density
relationship curve
Determine Optimum Moisture Content
and Maximum Dry Density
STEP 2 DETERMINE OPTIMUM MC amp MAX DENSITY
Modified Proctor
ASTM D1557
MOISTURE-DENSITY RELATIONSHIP
140
141
142
143
144
2 3 4 5 6 7 8
Dry
De
nsit
y (l
b
cf)
Moisture Content
Maximum density
Optimum moisture
- 26 -
COMPACTION VERY IMPORTANT
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
APPLICATIONS
Ports intermodal yards and military
hard stands
Warehouse facilities
Parking areas
Maintenance amp storage yards
Airport service areas
Arterial roads
Highway shoulders
Local streets amp intersections
Pothole patches
RCC ndash EXPERIENCING A RENEWAL
Originally used for heavy-duty pavements
Growth has accelerated in last decade
Increase in private amp public road use
Emergence of asphalt contractors placing RCC
000
050
100
150
200
250
-
2
4
6
8
10
12
14
16
18
20
Yearly R
CC
C
um
ula
tive
RC
C
(Mill
ion
SY
)
Yearly Sq Yds
Cumulative Sq Yds
(Millio
n S
Y)
1975 - 1999 2000-2010 2011-2013
of Projects 71 99 172
SY 2999771 8933250 4993296
Concrete PPI
Asphalt PPI
Paving Material PPI Price Comparisons1996 = 100
Source Bureau of Labor Statistics Producer Price Indices
VOLATILITY OF ASPHALT PRICES
- 8 -
RCC MAKES STRANGE BEDFELLOWS
- 9 -
BENEFITS OF ROLLER-COMPACTED CONCRETE
Fast construction
Economical
Early load carrying capacity
Supports heavy loads
Low maintenance
Durable
Light surface reduces lighting requirements
and Urban Heat Island effects
PROJECT CONSIDERATIONS
Project size
Site geometry
End use
Client expectations
- 11 -
SURFACE APPEARANCE
Asphalt RCCRCC Conventional
Concrete
Diamond
Ground
RCC
Diamond
Ground
Conventional
Concrete
frac34rdquo Max Sizefrac12rdquo Max Size
- 12 -
TECHNOLOGIES TO IMPROVE SURFACE APPEARANCE
bull Colloidal Silica
bull Reacts with cement to increase paste
bull Improves surface appearance
bull Reduces surface dusting
bull Improves surface durability
RCC
Surface
Pro
- 13 -
SURFACE APPEARANCE
Maryhill Catholic Cemetery Niles IL
Untreated
Treated
- 14 -
SURFACE APPEARANCE
Untreated
Treated
- 15 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 16 -
MIXTURE PROPORTIONING PHILOSOPHIES
- 17 -
RCC MIXTURE DESIGN
Modifications needed in typical no-slump concrete
mixture procedures (ACI 2113R) because RCC is
Dryer than zero slump
Not air-entrained
Lower cementitious content
Higher fines content
Nominal max size aggregate 12 to 34 in
- 18 -
CONVENTIONAL CONCRETE amp RCC
Percent by
Volume
Conventional Air-Entrained PCC
12 16 6 22 44
CM Water Air Fine Agg Coarse Agg
144 pcf
Roller Compacted Concrete
10 14 15 36 385CM Water Air Fine Agg Coarse Agg
153 pcf
- 19 -
SOIL COMPACTION METHOD
Most common method used in the US 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
(ASTM D1557)
3) Determine cementitious content
- 20 -
STEP 1 AGGREGATE SELECTION
Aggregate selection very important
85 of mix by volume
Responsible for mix workability
segregation amp ease of consolidation
Quality of aggregates should meet
ASTM C33
- 21 -
STEP 1 AGGREGATE SELECTION
Nominal Maximum Size Aggregate
ndash Most projects 58rdquo to 34rdquo
ndash As small as 12rdquo for tighter surface and reduced
segregation
ndash 1-12rdquo may be used for non-wearing courses or
where surface appearance is not critical
Plasticity Index (PI) lt 5
Multiple aggregate piles
Consider availability when preparing specs
(during design phase)
- 22 -
STEP 1 AGGREGATE SELECTION
0
10
20
30
40
50
60
70
80
90
100
Pe
rce
nt
Pa
sin
g
Sieve Number
RCCP Gradation Band
045 Power 34 MS Suggested Lower Limit Suggested Upper Limit
200100 416 38 12 34 1
5030 8
Size NumberPercent
Passing
1-in
(25 mm)100
34-in
(19mm)90-100
12-in
(125 mm)70-90
38-in
(95 mm)60-85
No 4
(475 mm)40-65
No 16
(118 mm)20-40
No 100
(150 mm)6-18
No 200
(75 mm)2-8
Suggested Blend
Gradation
PCA suggested
limits
045 Power
curve
- 23 -
Select a mid-range cement content
(eg 12 or 450 pcy)
Perform a modified Proctor test (ASTM
D1557)
Construct moisture-density
relationship curve
Determine Optimum Moisture Content
and Maximum Dry Density
STEP 2 DETERMINE OPTIMUM MC amp MAX DENSITY
Modified Proctor
ASTM D1557
MOISTURE-DENSITY RELATIONSHIP
140
141
142
143
144
2 3 4 5 6 7 8
Dry
De
nsit
y (l
b
cf)
Moisture Content
Maximum density
Optimum moisture
- 26 -
COMPACTION VERY IMPORTANT
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
RCC ndash EXPERIENCING A RENEWAL
Originally used for heavy-duty pavements
Growth has accelerated in last decade
Increase in private amp public road use
Emergence of asphalt contractors placing RCC
000
050
100
150
200
250
-
2
4
6
8
10
12
14
16
18
20
Yearly R
CC
C
um
ula
tive
RC
C
(Mill
ion
SY
)
Yearly Sq Yds
Cumulative Sq Yds
(Millio
n S
Y)
1975 - 1999 2000-2010 2011-2013
of Projects 71 99 172
SY 2999771 8933250 4993296
Concrete PPI
Asphalt PPI
Paving Material PPI Price Comparisons1996 = 100
Source Bureau of Labor Statistics Producer Price Indices
VOLATILITY OF ASPHALT PRICES
- 8 -
RCC MAKES STRANGE BEDFELLOWS
- 9 -
BENEFITS OF ROLLER-COMPACTED CONCRETE
Fast construction
Economical
Early load carrying capacity
Supports heavy loads
Low maintenance
Durable
Light surface reduces lighting requirements
and Urban Heat Island effects
PROJECT CONSIDERATIONS
Project size
Site geometry
End use
Client expectations
- 11 -
SURFACE APPEARANCE
Asphalt RCCRCC Conventional
Concrete
Diamond
Ground
RCC
Diamond
Ground
Conventional
Concrete
frac34rdquo Max Sizefrac12rdquo Max Size
- 12 -
TECHNOLOGIES TO IMPROVE SURFACE APPEARANCE
bull Colloidal Silica
bull Reacts with cement to increase paste
bull Improves surface appearance
bull Reduces surface dusting
bull Improves surface durability
RCC
Surface
Pro
- 13 -
SURFACE APPEARANCE
Maryhill Catholic Cemetery Niles IL
Untreated
Treated
- 14 -
SURFACE APPEARANCE
Untreated
Treated
- 15 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 16 -
MIXTURE PROPORTIONING PHILOSOPHIES
- 17 -
RCC MIXTURE DESIGN
Modifications needed in typical no-slump concrete
mixture procedures (ACI 2113R) because RCC is
Dryer than zero slump
Not air-entrained
Lower cementitious content
Higher fines content
Nominal max size aggregate 12 to 34 in
- 18 -
CONVENTIONAL CONCRETE amp RCC
Percent by
Volume
Conventional Air-Entrained PCC
12 16 6 22 44
CM Water Air Fine Agg Coarse Agg
144 pcf
Roller Compacted Concrete
10 14 15 36 385CM Water Air Fine Agg Coarse Agg
153 pcf
- 19 -
SOIL COMPACTION METHOD
Most common method used in the US 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
(ASTM D1557)
3) Determine cementitious content
- 20 -
STEP 1 AGGREGATE SELECTION
Aggregate selection very important
85 of mix by volume
Responsible for mix workability
segregation amp ease of consolidation
Quality of aggregates should meet
ASTM C33
- 21 -
STEP 1 AGGREGATE SELECTION
Nominal Maximum Size Aggregate
ndash Most projects 58rdquo to 34rdquo
ndash As small as 12rdquo for tighter surface and reduced
segregation
ndash 1-12rdquo may be used for non-wearing courses or
where surface appearance is not critical
Plasticity Index (PI) lt 5
Multiple aggregate piles
Consider availability when preparing specs
(during design phase)
- 22 -
STEP 1 AGGREGATE SELECTION
0
10
20
30
40
50
60
70
80
90
100
Pe
rce
nt
Pa
sin
g
Sieve Number
RCCP Gradation Band
045 Power 34 MS Suggested Lower Limit Suggested Upper Limit
200100 416 38 12 34 1
5030 8
Size NumberPercent
Passing
1-in
(25 mm)100
34-in
(19mm)90-100
12-in
(125 mm)70-90
38-in
(95 mm)60-85
No 4
(475 mm)40-65
No 16
(118 mm)20-40
No 100
(150 mm)6-18
No 200
(75 mm)2-8
Suggested Blend
Gradation
PCA suggested
limits
045 Power
curve
- 23 -
Select a mid-range cement content
(eg 12 or 450 pcy)
Perform a modified Proctor test (ASTM
D1557)
Construct moisture-density
relationship curve
Determine Optimum Moisture Content
and Maximum Dry Density
STEP 2 DETERMINE OPTIMUM MC amp MAX DENSITY
Modified Proctor
ASTM D1557
MOISTURE-DENSITY RELATIONSHIP
140
141
142
143
144
2 3 4 5 6 7 8
Dry
De
nsit
y (l
b
cf)
Moisture Content
Maximum density
Optimum moisture
- 26 -
COMPACTION VERY IMPORTANT
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
Concrete PPI
Asphalt PPI
Paving Material PPI Price Comparisons1996 = 100
Source Bureau of Labor Statistics Producer Price Indices
VOLATILITY OF ASPHALT PRICES
- 8 -
RCC MAKES STRANGE BEDFELLOWS
- 9 -
BENEFITS OF ROLLER-COMPACTED CONCRETE
Fast construction
Economical
Early load carrying capacity
Supports heavy loads
Low maintenance
Durable
Light surface reduces lighting requirements
and Urban Heat Island effects
PROJECT CONSIDERATIONS
Project size
Site geometry
End use
Client expectations
- 11 -
SURFACE APPEARANCE
Asphalt RCCRCC Conventional
Concrete
Diamond
Ground
RCC
Diamond
Ground
Conventional
Concrete
frac34rdquo Max Sizefrac12rdquo Max Size
- 12 -
TECHNOLOGIES TO IMPROVE SURFACE APPEARANCE
bull Colloidal Silica
bull Reacts with cement to increase paste
bull Improves surface appearance
bull Reduces surface dusting
bull Improves surface durability
RCC
Surface
Pro
- 13 -
SURFACE APPEARANCE
Maryhill Catholic Cemetery Niles IL
Untreated
Treated
- 14 -
SURFACE APPEARANCE
Untreated
Treated
- 15 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 16 -
MIXTURE PROPORTIONING PHILOSOPHIES
- 17 -
RCC MIXTURE DESIGN
Modifications needed in typical no-slump concrete
mixture procedures (ACI 2113R) because RCC is
Dryer than zero slump
Not air-entrained
Lower cementitious content
Higher fines content
Nominal max size aggregate 12 to 34 in
- 18 -
CONVENTIONAL CONCRETE amp RCC
Percent by
Volume
Conventional Air-Entrained PCC
12 16 6 22 44
CM Water Air Fine Agg Coarse Agg
144 pcf
Roller Compacted Concrete
10 14 15 36 385CM Water Air Fine Agg Coarse Agg
153 pcf
- 19 -
SOIL COMPACTION METHOD
Most common method used in the US 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
(ASTM D1557)
3) Determine cementitious content
- 20 -
STEP 1 AGGREGATE SELECTION
Aggregate selection very important
85 of mix by volume
Responsible for mix workability
segregation amp ease of consolidation
Quality of aggregates should meet
ASTM C33
- 21 -
STEP 1 AGGREGATE SELECTION
Nominal Maximum Size Aggregate
ndash Most projects 58rdquo to 34rdquo
ndash As small as 12rdquo for tighter surface and reduced
segregation
ndash 1-12rdquo may be used for non-wearing courses or
where surface appearance is not critical
Plasticity Index (PI) lt 5
Multiple aggregate piles
Consider availability when preparing specs
(during design phase)
- 22 -
STEP 1 AGGREGATE SELECTION
0
10
20
30
40
50
60
70
80
90
100
Pe
rce
nt
Pa
sin
g
Sieve Number
RCCP Gradation Band
045 Power 34 MS Suggested Lower Limit Suggested Upper Limit
200100 416 38 12 34 1
5030 8
Size NumberPercent
Passing
1-in
(25 mm)100
34-in
(19mm)90-100
12-in
(125 mm)70-90
38-in
(95 mm)60-85
No 4
(475 mm)40-65
No 16
(118 mm)20-40
No 100
(150 mm)6-18
No 200
(75 mm)2-8
Suggested Blend
Gradation
PCA suggested
limits
045 Power
curve
- 23 -
Select a mid-range cement content
(eg 12 or 450 pcy)
Perform a modified Proctor test (ASTM
D1557)
Construct moisture-density
relationship curve
Determine Optimum Moisture Content
and Maximum Dry Density
STEP 2 DETERMINE OPTIMUM MC amp MAX DENSITY
Modified Proctor
ASTM D1557
MOISTURE-DENSITY RELATIONSHIP
140
141
142
143
144
2 3 4 5 6 7 8
Dry
De
nsit
y (l
b
cf)
Moisture Content
Maximum density
Optimum moisture
- 26 -
COMPACTION VERY IMPORTANT
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 8 -
RCC MAKES STRANGE BEDFELLOWS
- 9 -
BENEFITS OF ROLLER-COMPACTED CONCRETE
Fast construction
Economical
Early load carrying capacity
Supports heavy loads
Low maintenance
Durable
Light surface reduces lighting requirements
and Urban Heat Island effects
PROJECT CONSIDERATIONS
Project size
Site geometry
End use
Client expectations
- 11 -
SURFACE APPEARANCE
Asphalt RCCRCC Conventional
Concrete
Diamond
Ground
RCC
Diamond
Ground
Conventional
Concrete
frac34rdquo Max Sizefrac12rdquo Max Size
- 12 -
TECHNOLOGIES TO IMPROVE SURFACE APPEARANCE
bull Colloidal Silica
bull Reacts with cement to increase paste
bull Improves surface appearance
bull Reduces surface dusting
bull Improves surface durability
RCC
Surface
Pro
- 13 -
SURFACE APPEARANCE
Maryhill Catholic Cemetery Niles IL
Untreated
Treated
- 14 -
SURFACE APPEARANCE
Untreated
Treated
- 15 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 16 -
MIXTURE PROPORTIONING PHILOSOPHIES
- 17 -
RCC MIXTURE DESIGN
Modifications needed in typical no-slump concrete
mixture procedures (ACI 2113R) because RCC is
Dryer than zero slump
Not air-entrained
Lower cementitious content
Higher fines content
Nominal max size aggregate 12 to 34 in
- 18 -
CONVENTIONAL CONCRETE amp RCC
Percent by
Volume
Conventional Air-Entrained PCC
12 16 6 22 44
CM Water Air Fine Agg Coarse Agg
144 pcf
Roller Compacted Concrete
10 14 15 36 385CM Water Air Fine Agg Coarse Agg
153 pcf
- 19 -
SOIL COMPACTION METHOD
Most common method used in the US 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
(ASTM D1557)
3) Determine cementitious content
- 20 -
STEP 1 AGGREGATE SELECTION
Aggregate selection very important
85 of mix by volume
Responsible for mix workability
segregation amp ease of consolidation
Quality of aggregates should meet
ASTM C33
- 21 -
STEP 1 AGGREGATE SELECTION
Nominal Maximum Size Aggregate
ndash Most projects 58rdquo to 34rdquo
ndash As small as 12rdquo for tighter surface and reduced
segregation
ndash 1-12rdquo may be used for non-wearing courses or
where surface appearance is not critical
Plasticity Index (PI) lt 5
Multiple aggregate piles
Consider availability when preparing specs
(during design phase)
- 22 -
STEP 1 AGGREGATE SELECTION
0
10
20
30
40
50
60
70
80
90
100
Pe
rce
nt
Pa
sin
g
Sieve Number
RCCP Gradation Band
045 Power 34 MS Suggested Lower Limit Suggested Upper Limit
200100 416 38 12 34 1
5030 8
Size NumberPercent
Passing
1-in
(25 mm)100
34-in
(19mm)90-100
12-in
(125 mm)70-90
38-in
(95 mm)60-85
No 4
(475 mm)40-65
No 16
(118 mm)20-40
No 100
(150 mm)6-18
No 200
(75 mm)2-8
Suggested Blend
Gradation
PCA suggested
limits
045 Power
curve
- 23 -
Select a mid-range cement content
(eg 12 or 450 pcy)
Perform a modified Proctor test (ASTM
D1557)
Construct moisture-density
relationship curve
Determine Optimum Moisture Content
and Maximum Dry Density
STEP 2 DETERMINE OPTIMUM MC amp MAX DENSITY
Modified Proctor
ASTM D1557
MOISTURE-DENSITY RELATIONSHIP
140
141
142
143
144
2 3 4 5 6 7 8
Dry
De
nsit
y (l
b
cf)
Moisture Content
Maximum density
Optimum moisture
- 26 -
COMPACTION VERY IMPORTANT
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 9 -
BENEFITS OF ROLLER-COMPACTED CONCRETE
Fast construction
Economical
Early load carrying capacity
Supports heavy loads
Low maintenance
Durable
Light surface reduces lighting requirements
and Urban Heat Island effects
PROJECT CONSIDERATIONS
Project size
Site geometry
End use
Client expectations
- 11 -
SURFACE APPEARANCE
Asphalt RCCRCC Conventional
Concrete
Diamond
Ground
RCC
Diamond
Ground
Conventional
Concrete
frac34rdquo Max Sizefrac12rdquo Max Size
- 12 -
TECHNOLOGIES TO IMPROVE SURFACE APPEARANCE
bull Colloidal Silica
bull Reacts with cement to increase paste
bull Improves surface appearance
bull Reduces surface dusting
bull Improves surface durability
RCC
Surface
Pro
- 13 -
SURFACE APPEARANCE
Maryhill Catholic Cemetery Niles IL
Untreated
Treated
- 14 -
SURFACE APPEARANCE
Untreated
Treated
- 15 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 16 -
MIXTURE PROPORTIONING PHILOSOPHIES
- 17 -
RCC MIXTURE DESIGN
Modifications needed in typical no-slump concrete
mixture procedures (ACI 2113R) because RCC is
Dryer than zero slump
Not air-entrained
Lower cementitious content
Higher fines content
Nominal max size aggregate 12 to 34 in
- 18 -
CONVENTIONAL CONCRETE amp RCC
Percent by
Volume
Conventional Air-Entrained PCC
12 16 6 22 44
CM Water Air Fine Agg Coarse Agg
144 pcf
Roller Compacted Concrete
10 14 15 36 385CM Water Air Fine Agg Coarse Agg
153 pcf
- 19 -
SOIL COMPACTION METHOD
Most common method used in the US 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
(ASTM D1557)
3) Determine cementitious content
- 20 -
STEP 1 AGGREGATE SELECTION
Aggregate selection very important
85 of mix by volume
Responsible for mix workability
segregation amp ease of consolidation
Quality of aggregates should meet
ASTM C33
- 21 -
STEP 1 AGGREGATE SELECTION
Nominal Maximum Size Aggregate
ndash Most projects 58rdquo to 34rdquo
ndash As small as 12rdquo for tighter surface and reduced
segregation
ndash 1-12rdquo may be used for non-wearing courses or
where surface appearance is not critical
Plasticity Index (PI) lt 5
Multiple aggregate piles
Consider availability when preparing specs
(during design phase)
- 22 -
STEP 1 AGGREGATE SELECTION
0
10
20
30
40
50
60
70
80
90
100
Pe
rce
nt
Pa
sin
g
Sieve Number
RCCP Gradation Band
045 Power 34 MS Suggested Lower Limit Suggested Upper Limit
200100 416 38 12 34 1
5030 8
Size NumberPercent
Passing
1-in
(25 mm)100
34-in
(19mm)90-100
12-in
(125 mm)70-90
38-in
(95 mm)60-85
No 4
(475 mm)40-65
No 16
(118 mm)20-40
No 100
(150 mm)6-18
No 200
(75 mm)2-8
Suggested Blend
Gradation
PCA suggested
limits
045 Power
curve
- 23 -
Select a mid-range cement content
(eg 12 or 450 pcy)
Perform a modified Proctor test (ASTM
D1557)
Construct moisture-density
relationship curve
Determine Optimum Moisture Content
and Maximum Dry Density
STEP 2 DETERMINE OPTIMUM MC amp MAX DENSITY
Modified Proctor
ASTM D1557
MOISTURE-DENSITY RELATIONSHIP
140
141
142
143
144
2 3 4 5 6 7 8
Dry
De
nsit
y (l
b
cf)
Moisture Content
Maximum density
Optimum moisture
- 26 -
COMPACTION VERY IMPORTANT
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
PROJECT CONSIDERATIONS
Project size
Site geometry
End use
Client expectations
- 11 -
SURFACE APPEARANCE
Asphalt RCCRCC Conventional
Concrete
Diamond
Ground
RCC
Diamond
Ground
Conventional
Concrete
frac34rdquo Max Sizefrac12rdquo Max Size
- 12 -
TECHNOLOGIES TO IMPROVE SURFACE APPEARANCE
bull Colloidal Silica
bull Reacts with cement to increase paste
bull Improves surface appearance
bull Reduces surface dusting
bull Improves surface durability
RCC
Surface
Pro
- 13 -
SURFACE APPEARANCE
Maryhill Catholic Cemetery Niles IL
Untreated
Treated
- 14 -
SURFACE APPEARANCE
Untreated
Treated
- 15 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 16 -
MIXTURE PROPORTIONING PHILOSOPHIES
- 17 -
RCC MIXTURE DESIGN
Modifications needed in typical no-slump concrete
mixture procedures (ACI 2113R) because RCC is
Dryer than zero slump
Not air-entrained
Lower cementitious content
Higher fines content
Nominal max size aggregate 12 to 34 in
- 18 -
CONVENTIONAL CONCRETE amp RCC
Percent by
Volume
Conventional Air-Entrained PCC
12 16 6 22 44
CM Water Air Fine Agg Coarse Agg
144 pcf
Roller Compacted Concrete
10 14 15 36 385CM Water Air Fine Agg Coarse Agg
153 pcf
- 19 -
SOIL COMPACTION METHOD
Most common method used in the US 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
(ASTM D1557)
3) Determine cementitious content
- 20 -
STEP 1 AGGREGATE SELECTION
Aggregate selection very important
85 of mix by volume
Responsible for mix workability
segregation amp ease of consolidation
Quality of aggregates should meet
ASTM C33
- 21 -
STEP 1 AGGREGATE SELECTION
Nominal Maximum Size Aggregate
ndash Most projects 58rdquo to 34rdquo
ndash As small as 12rdquo for tighter surface and reduced
segregation
ndash 1-12rdquo may be used for non-wearing courses or
where surface appearance is not critical
Plasticity Index (PI) lt 5
Multiple aggregate piles
Consider availability when preparing specs
(during design phase)
- 22 -
STEP 1 AGGREGATE SELECTION
0
10
20
30
40
50
60
70
80
90
100
Pe
rce
nt
Pa
sin
g
Sieve Number
RCCP Gradation Band
045 Power 34 MS Suggested Lower Limit Suggested Upper Limit
200100 416 38 12 34 1
5030 8
Size NumberPercent
Passing
1-in
(25 mm)100
34-in
(19mm)90-100
12-in
(125 mm)70-90
38-in
(95 mm)60-85
No 4
(475 mm)40-65
No 16
(118 mm)20-40
No 100
(150 mm)6-18
No 200
(75 mm)2-8
Suggested Blend
Gradation
PCA suggested
limits
045 Power
curve
- 23 -
Select a mid-range cement content
(eg 12 or 450 pcy)
Perform a modified Proctor test (ASTM
D1557)
Construct moisture-density
relationship curve
Determine Optimum Moisture Content
and Maximum Dry Density
STEP 2 DETERMINE OPTIMUM MC amp MAX DENSITY
Modified Proctor
ASTM D1557
MOISTURE-DENSITY RELATIONSHIP
140
141
142
143
144
2 3 4 5 6 7 8
Dry
De
nsit
y (l
b
cf)
Moisture Content
Maximum density
Optimum moisture
- 26 -
COMPACTION VERY IMPORTANT
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 11 -
SURFACE APPEARANCE
Asphalt RCCRCC Conventional
Concrete
Diamond
Ground
RCC
Diamond
Ground
Conventional
Concrete
frac34rdquo Max Sizefrac12rdquo Max Size
- 12 -
TECHNOLOGIES TO IMPROVE SURFACE APPEARANCE
bull Colloidal Silica
bull Reacts with cement to increase paste
bull Improves surface appearance
bull Reduces surface dusting
bull Improves surface durability
RCC
Surface
Pro
- 13 -
SURFACE APPEARANCE
Maryhill Catholic Cemetery Niles IL
Untreated
Treated
- 14 -
SURFACE APPEARANCE
Untreated
Treated
- 15 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 16 -
MIXTURE PROPORTIONING PHILOSOPHIES
- 17 -
RCC MIXTURE DESIGN
Modifications needed in typical no-slump concrete
mixture procedures (ACI 2113R) because RCC is
Dryer than zero slump
Not air-entrained
Lower cementitious content
Higher fines content
Nominal max size aggregate 12 to 34 in
- 18 -
CONVENTIONAL CONCRETE amp RCC
Percent by
Volume
Conventional Air-Entrained PCC
12 16 6 22 44
CM Water Air Fine Agg Coarse Agg
144 pcf
Roller Compacted Concrete
10 14 15 36 385CM Water Air Fine Agg Coarse Agg
153 pcf
- 19 -
SOIL COMPACTION METHOD
Most common method used in the US 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
(ASTM D1557)
3) Determine cementitious content
- 20 -
STEP 1 AGGREGATE SELECTION
Aggregate selection very important
85 of mix by volume
Responsible for mix workability
segregation amp ease of consolidation
Quality of aggregates should meet
ASTM C33
- 21 -
STEP 1 AGGREGATE SELECTION
Nominal Maximum Size Aggregate
ndash Most projects 58rdquo to 34rdquo
ndash As small as 12rdquo for tighter surface and reduced
segregation
ndash 1-12rdquo may be used for non-wearing courses or
where surface appearance is not critical
Plasticity Index (PI) lt 5
Multiple aggregate piles
Consider availability when preparing specs
(during design phase)
- 22 -
STEP 1 AGGREGATE SELECTION
0
10
20
30
40
50
60
70
80
90
100
Pe
rce
nt
Pa
sin
g
Sieve Number
RCCP Gradation Band
045 Power 34 MS Suggested Lower Limit Suggested Upper Limit
200100 416 38 12 34 1
5030 8
Size NumberPercent
Passing
1-in
(25 mm)100
34-in
(19mm)90-100
12-in
(125 mm)70-90
38-in
(95 mm)60-85
No 4
(475 mm)40-65
No 16
(118 mm)20-40
No 100
(150 mm)6-18
No 200
(75 mm)2-8
Suggested Blend
Gradation
PCA suggested
limits
045 Power
curve
- 23 -
Select a mid-range cement content
(eg 12 or 450 pcy)
Perform a modified Proctor test (ASTM
D1557)
Construct moisture-density
relationship curve
Determine Optimum Moisture Content
and Maximum Dry Density
STEP 2 DETERMINE OPTIMUM MC amp MAX DENSITY
Modified Proctor
ASTM D1557
MOISTURE-DENSITY RELATIONSHIP
140
141
142
143
144
2 3 4 5 6 7 8
Dry
De
nsit
y (l
b
cf)
Moisture Content
Maximum density
Optimum moisture
- 26 -
COMPACTION VERY IMPORTANT
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 12 -
TECHNOLOGIES TO IMPROVE SURFACE APPEARANCE
bull Colloidal Silica
bull Reacts with cement to increase paste
bull Improves surface appearance
bull Reduces surface dusting
bull Improves surface durability
RCC
Surface
Pro
- 13 -
SURFACE APPEARANCE
Maryhill Catholic Cemetery Niles IL
Untreated
Treated
- 14 -
SURFACE APPEARANCE
Untreated
Treated
- 15 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 16 -
MIXTURE PROPORTIONING PHILOSOPHIES
- 17 -
RCC MIXTURE DESIGN
Modifications needed in typical no-slump concrete
mixture procedures (ACI 2113R) because RCC is
Dryer than zero slump
Not air-entrained
Lower cementitious content
Higher fines content
Nominal max size aggregate 12 to 34 in
- 18 -
CONVENTIONAL CONCRETE amp RCC
Percent by
Volume
Conventional Air-Entrained PCC
12 16 6 22 44
CM Water Air Fine Agg Coarse Agg
144 pcf
Roller Compacted Concrete
10 14 15 36 385CM Water Air Fine Agg Coarse Agg
153 pcf
- 19 -
SOIL COMPACTION METHOD
Most common method used in the US 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
(ASTM D1557)
3) Determine cementitious content
- 20 -
STEP 1 AGGREGATE SELECTION
Aggregate selection very important
85 of mix by volume
Responsible for mix workability
segregation amp ease of consolidation
Quality of aggregates should meet
ASTM C33
- 21 -
STEP 1 AGGREGATE SELECTION
Nominal Maximum Size Aggregate
ndash Most projects 58rdquo to 34rdquo
ndash As small as 12rdquo for tighter surface and reduced
segregation
ndash 1-12rdquo may be used for non-wearing courses or
where surface appearance is not critical
Plasticity Index (PI) lt 5
Multiple aggregate piles
Consider availability when preparing specs
(during design phase)
- 22 -
STEP 1 AGGREGATE SELECTION
0
10
20
30
40
50
60
70
80
90
100
Pe
rce
nt
Pa
sin
g
Sieve Number
RCCP Gradation Band
045 Power 34 MS Suggested Lower Limit Suggested Upper Limit
200100 416 38 12 34 1
5030 8
Size NumberPercent
Passing
1-in
(25 mm)100
34-in
(19mm)90-100
12-in
(125 mm)70-90
38-in
(95 mm)60-85
No 4
(475 mm)40-65
No 16
(118 mm)20-40
No 100
(150 mm)6-18
No 200
(75 mm)2-8
Suggested Blend
Gradation
PCA suggested
limits
045 Power
curve
- 23 -
Select a mid-range cement content
(eg 12 or 450 pcy)
Perform a modified Proctor test (ASTM
D1557)
Construct moisture-density
relationship curve
Determine Optimum Moisture Content
and Maximum Dry Density
STEP 2 DETERMINE OPTIMUM MC amp MAX DENSITY
Modified Proctor
ASTM D1557
MOISTURE-DENSITY RELATIONSHIP
140
141
142
143
144
2 3 4 5 6 7 8
Dry
De
nsit
y (l
b
cf)
Moisture Content
Maximum density
Optimum moisture
- 26 -
COMPACTION VERY IMPORTANT
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 13 -
SURFACE APPEARANCE
Maryhill Catholic Cemetery Niles IL
Untreated
Treated
- 14 -
SURFACE APPEARANCE
Untreated
Treated
- 15 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 16 -
MIXTURE PROPORTIONING PHILOSOPHIES
- 17 -
RCC MIXTURE DESIGN
Modifications needed in typical no-slump concrete
mixture procedures (ACI 2113R) because RCC is
Dryer than zero slump
Not air-entrained
Lower cementitious content
Higher fines content
Nominal max size aggregate 12 to 34 in
- 18 -
CONVENTIONAL CONCRETE amp RCC
Percent by
Volume
Conventional Air-Entrained PCC
12 16 6 22 44
CM Water Air Fine Agg Coarse Agg
144 pcf
Roller Compacted Concrete
10 14 15 36 385CM Water Air Fine Agg Coarse Agg
153 pcf
- 19 -
SOIL COMPACTION METHOD
Most common method used in the US 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
(ASTM D1557)
3) Determine cementitious content
- 20 -
STEP 1 AGGREGATE SELECTION
Aggregate selection very important
85 of mix by volume
Responsible for mix workability
segregation amp ease of consolidation
Quality of aggregates should meet
ASTM C33
- 21 -
STEP 1 AGGREGATE SELECTION
Nominal Maximum Size Aggregate
ndash Most projects 58rdquo to 34rdquo
ndash As small as 12rdquo for tighter surface and reduced
segregation
ndash 1-12rdquo may be used for non-wearing courses or
where surface appearance is not critical
Plasticity Index (PI) lt 5
Multiple aggregate piles
Consider availability when preparing specs
(during design phase)
- 22 -
STEP 1 AGGREGATE SELECTION
0
10
20
30
40
50
60
70
80
90
100
Pe
rce
nt
Pa
sin
g
Sieve Number
RCCP Gradation Band
045 Power 34 MS Suggested Lower Limit Suggested Upper Limit
200100 416 38 12 34 1
5030 8
Size NumberPercent
Passing
1-in
(25 mm)100
34-in
(19mm)90-100
12-in
(125 mm)70-90
38-in
(95 mm)60-85
No 4
(475 mm)40-65
No 16
(118 mm)20-40
No 100
(150 mm)6-18
No 200
(75 mm)2-8
Suggested Blend
Gradation
PCA suggested
limits
045 Power
curve
- 23 -
Select a mid-range cement content
(eg 12 or 450 pcy)
Perform a modified Proctor test (ASTM
D1557)
Construct moisture-density
relationship curve
Determine Optimum Moisture Content
and Maximum Dry Density
STEP 2 DETERMINE OPTIMUM MC amp MAX DENSITY
Modified Proctor
ASTM D1557
MOISTURE-DENSITY RELATIONSHIP
140
141
142
143
144
2 3 4 5 6 7 8
Dry
De
nsit
y (l
b
cf)
Moisture Content
Maximum density
Optimum moisture
- 26 -
COMPACTION VERY IMPORTANT
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 14 -
SURFACE APPEARANCE
Untreated
Treated
- 15 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 16 -
MIXTURE PROPORTIONING PHILOSOPHIES
- 17 -
RCC MIXTURE DESIGN
Modifications needed in typical no-slump concrete
mixture procedures (ACI 2113R) because RCC is
Dryer than zero slump
Not air-entrained
Lower cementitious content
Higher fines content
Nominal max size aggregate 12 to 34 in
- 18 -
CONVENTIONAL CONCRETE amp RCC
Percent by
Volume
Conventional Air-Entrained PCC
12 16 6 22 44
CM Water Air Fine Agg Coarse Agg
144 pcf
Roller Compacted Concrete
10 14 15 36 385CM Water Air Fine Agg Coarse Agg
153 pcf
- 19 -
SOIL COMPACTION METHOD
Most common method used in the US 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
(ASTM D1557)
3) Determine cementitious content
- 20 -
STEP 1 AGGREGATE SELECTION
Aggregate selection very important
85 of mix by volume
Responsible for mix workability
segregation amp ease of consolidation
Quality of aggregates should meet
ASTM C33
- 21 -
STEP 1 AGGREGATE SELECTION
Nominal Maximum Size Aggregate
ndash Most projects 58rdquo to 34rdquo
ndash As small as 12rdquo for tighter surface and reduced
segregation
ndash 1-12rdquo may be used for non-wearing courses or
where surface appearance is not critical
Plasticity Index (PI) lt 5
Multiple aggregate piles
Consider availability when preparing specs
(during design phase)
- 22 -
STEP 1 AGGREGATE SELECTION
0
10
20
30
40
50
60
70
80
90
100
Pe
rce
nt
Pa
sin
g
Sieve Number
RCCP Gradation Band
045 Power 34 MS Suggested Lower Limit Suggested Upper Limit
200100 416 38 12 34 1
5030 8
Size NumberPercent
Passing
1-in
(25 mm)100
34-in
(19mm)90-100
12-in
(125 mm)70-90
38-in
(95 mm)60-85
No 4
(475 mm)40-65
No 16
(118 mm)20-40
No 100
(150 mm)6-18
No 200
(75 mm)2-8
Suggested Blend
Gradation
PCA suggested
limits
045 Power
curve
- 23 -
Select a mid-range cement content
(eg 12 or 450 pcy)
Perform a modified Proctor test (ASTM
D1557)
Construct moisture-density
relationship curve
Determine Optimum Moisture Content
and Maximum Dry Density
STEP 2 DETERMINE OPTIMUM MC amp MAX DENSITY
Modified Proctor
ASTM D1557
MOISTURE-DENSITY RELATIONSHIP
140
141
142
143
144
2 3 4 5 6 7 8
Dry
De
nsit
y (l
b
cf)
Moisture Content
Maximum density
Optimum moisture
- 26 -
COMPACTION VERY IMPORTANT
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 15 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 16 -
MIXTURE PROPORTIONING PHILOSOPHIES
- 17 -
RCC MIXTURE DESIGN
Modifications needed in typical no-slump concrete
mixture procedures (ACI 2113R) because RCC is
Dryer than zero slump
Not air-entrained
Lower cementitious content
Higher fines content
Nominal max size aggregate 12 to 34 in
- 18 -
CONVENTIONAL CONCRETE amp RCC
Percent by
Volume
Conventional Air-Entrained PCC
12 16 6 22 44
CM Water Air Fine Agg Coarse Agg
144 pcf
Roller Compacted Concrete
10 14 15 36 385CM Water Air Fine Agg Coarse Agg
153 pcf
- 19 -
SOIL COMPACTION METHOD
Most common method used in the US 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
(ASTM D1557)
3) Determine cementitious content
- 20 -
STEP 1 AGGREGATE SELECTION
Aggregate selection very important
85 of mix by volume
Responsible for mix workability
segregation amp ease of consolidation
Quality of aggregates should meet
ASTM C33
- 21 -
STEP 1 AGGREGATE SELECTION
Nominal Maximum Size Aggregate
ndash Most projects 58rdquo to 34rdquo
ndash As small as 12rdquo for tighter surface and reduced
segregation
ndash 1-12rdquo may be used for non-wearing courses or
where surface appearance is not critical
Plasticity Index (PI) lt 5
Multiple aggregate piles
Consider availability when preparing specs
(during design phase)
- 22 -
STEP 1 AGGREGATE SELECTION
0
10
20
30
40
50
60
70
80
90
100
Pe
rce
nt
Pa
sin
g
Sieve Number
RCCP Gradation Band
045 Power 34 MS Suggested Lower Limit Suggested Upper Limit
200100 416 38 12 34 1
5030 8
Size NumberPercent
Passing
1-in
(25 mm)100
34-in
(19mm)90-100
12-in
(125 mm)70-90
38-in
(95 mm)60-85
No 4
(475 mm)40-65
No 16
(118 mm)20-40
No 100
(150 mm)6-18
No 200
(75 mm)2-8
Suggested Blend
Gradation
PCA suggested
limits
045 Power
curve
- 23 -
Select a mid-range cement content
(eg 12 or 450 pcy)
Perform a modified Proctor test (ASTM
D1557)
Construct moisture-density
relationship curve
Determine Optimum Moisture Content
and Maximum Dry Density
STEP 2 DETERMINE OPTIMUM MC amp MAX DENSITY
Modified Proctor
ASTM D1557
MOISTURE-DENSITY RELATIONSHIP
140
141
142
143
144
2 3 4 5 6 7 8
Dry
De
nsit
y (l
b
cf)
Moisture Content
Maximum density
Optimum moisture
- 26 -
COMPACTION VERY IMPORTANT
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 16 -
MIXTURE PROPORTIONING PHILOSOPHIES
- 17 -
RCC MIXTURE DESIGN
Modifications needed in typical no-slump concrete
mixture procedures (ACI 2113R) because RCC is
Dryer than zero slump
Not air-entrained
Lower cementitious content
Higher fines content
Nominal max size aggregate 12 to 34 in
- 18 -
CONVENTIONAL CONCRETE amp RCC
Percent by
Volume
Conventional Air-Entrained PCC
12 16 6 22 44
CM Water Air Fine Agg Coarse Agg
144 pcf
Roller Compacted Concrete
10 14 15 36 385CM Water Air Fine Agg Coarse Agg
153 pcf
- 19 -
SOIL COMPACTION METHOD
Most common method used in the US 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
(ASTM D1557)
3) Determine cementitious content
- 20 -
STEP 1 AGGREGATE SELECTION
Aggregate selection very important
85 of mix by volume
Responsible for mix workability
segregation amp ease of consolidation
Quality of aggregates should meet
ASTM C33
- 21 -
STEP 1 AGGREGATE SELECTION
Nominal Maximum Size Aggregate
ndash Most projects 58rdquo to 34rdquo
ndash As small as 12rdquo for tighter surface and reduced
segregation
ndash 1-12rdquo may be used for non-wearing courses or
where surface appearance is not critical
Plasticity Index (PI) lt 5
Multiple aggregate piles
Consider availability when preparing specs
(during design phase)
- 22 -
STEP 1 AGGREGATE SELECTION
0
10
20
30
40
50
60
70
80
90
100
Pe
rce
nt
Pa
sin
g
Sieve Number
RCCP Gradation Band
045 Power 34 MS Suggested Lower Limit Suggested Upper Limit
200100 416 38 12 34 1
5030 8
Size NumberPercent
Passing
1-in
(25 mm)100
34-in
(19mm)90-100
12-in
(125 mm)70-90
38-in
(95 mm)60-85
No 4
(475 mm)40-65
No 16
(118 mm)20-40
No 100
(150 mm)6-18
No 200
(75 mm)2-8
Suggested Blend
Gradation
PCA suggested
limits
045 Power
curve
- 23 -
Select a mid-range cement content
(eg 12 or 450 pcy)
Perform a modified Proctor test (ASTM
D1557)
Construct moisture-density
relationship curve
Determine Optimum Moisture Content
and Maximum Dry Density
STEP 2 DETERMINE OPTIMUM MC amp MAX DENSITY
Modified Proctor
ASTM D1557
MOISTURE-DENSITY RELATIONSHIP
140
141
142
143
144
2 3 4 5 6 7 8
Dry
De
nsit
y (l
b
cf)
Moisture Content
Maximum density
Optimum moisture
- 26 -
COMPACTION VERY IMPORTANT
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 17 -
RCC MIXTURE DESIGN
Modifications needed in typical no-slump concrete
mixture procedures (ACI 2113R) because RCC is
Dryer than zero slump
Not air-entrained
Lower cementitious content
Higher fines content
Nominal max size aggregate 12 to 34 in
- 18 -
CONVENTIONAL CONCRETE amp RCC
Percent by
Volume
Conventional Air-Entrained PCC
12 16 6 22 44
CM Water Air Fine Agg Coarse Agg
144 pcf
Roller Compacted Concrete
10 14 15 36 385CM Water Air Fine Agg Coarse Agg
153 pcf
- 19 -
SOIL COMPACTION METHOD
Most common method used in the US 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
(ASTM D1557)
3) Determine cementitious content
- 20 -
STEP 1 AGGREGATE SELECTION
Aggregate selection very important
85 of mix by volume
Responsible for mix workability
segregation amp ease of consolidation
Quality of aggregates should meet
ASTM C33
- 21 -
STEP 1 AGGREGATE SELECTION
Nominal Maximum Size Aggregate
ndash Most projects 58rdquo to 34rdquo
ndash As small as 12rdquo for tighter surface and reduced
segregation
ndash 1-12rdquo may be used for non-wearing courses or
where surface appearance is not critical
Plasticity Index (PI) lt 5
Multiple aggregate piles
Consider availability when preparing specs
(during design phase)
- 22 -
STEP 1 AGGREGATE SELECTION
0
10
20
30
40
50
60
70
80
90
100
Pe
rce
nt
Pa
sin
g
Sieve Number
RCCP Gradation Band
045 Power 34 MS Suggested Lower Limit Suggested Upper Limit
200100 416 38 12 34 1
5030 8
Size NumberPercent
Passing
1-in
(25 mm)100
34-in
(19mm)90-100
12-in
(125 mm)70-90
38-in
(95 mm)60-85
No 4
(475 mm)40-65
No 16
(118 mm)20-40
No 100
(150 mm)6-18
No 200
(75 mm)2-8
Suggested Blend
Gradation
PCA suggested
limits
045 Power
curve
- 23 -
Select a mid-range cement content
(eg 12 or 450 pcy)
Perform a modified Proctor test (ASTM
D1557)
Construct moisture-density
relationship curve
Determine Optimum Moisture Content
and Maximum Dry Density
STEP 2 DETERMINE OPTIMUM MC amp MAX DENSITY
Modified Proctor
ASTM D1557
MOISTURE-DENSITY RELATIONSHIP
140
141
142
143
144
2 3 4 5 6 7 8
Dry
De
nsit
y (l
b
cf)
Moisture Content
Maximum density
Optimum moisture
- 26 -
COMPACTION VERY IMPORTANT
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 18 -
CONVENTIONAL CONCRETE amp RCC
Percent by
Volume
Conventional Air-Entrained PCC
12 16 6 22 44
CM Water Air Fine Agg Coarse Agg
144 pcf
Roller Compacted Concrete
10 14 15 36 385CM Water Air Fine Agg Coarse Agg
153 pcf
- 19 -
SOIL COMPACTION METHOD
Most common method used in the US 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
(ASTM D1557)
3) Determine cementitious content
- 20 -
STEP 1 AGGREGATE SELECTION
Aggregate selection very important
85 of mix by volume
Responsible for mix workability
segregation amp ease of consolidation
Quality of aggregates should meet
ASTM C33
- 21 -
STEP 1 AGGREGATE SELECTION
Nominal Maximum Size Aggregate
ndash Most projects 58rdquo to 34rdquo
ndash As small as 12rdquo for tighter surface and reduced
segregation
ndash 1-12rdquo may be used for non-wearing courses or
where surface appearance is not critical
Plasticity Index (PI) lt 5
Multiple aggregate piles
Consider availability when preparing specs
(during design phase)
- 22 -
STEP 1 AGGREGATE SELECTION
0
10
20
30
40
50
60
70
80
90
100
Pe
rce
nt
Pa
sin
g
Sieve Number
RCCP Gradation Band
045 Power 34 MS Suggested Lower Limit Suggested Upper Limit
200100 416 38 12 34 1
5030 8
Size NumberPercent
Passing
1-in
(25 mm)100
34-in
(19mm)90-100
12-in
(125 mm)70-90
38-in
(95 mm)60-85
No 4
(475 mm)40-65
No 16
(118 mm)20-40
No 100
(150 mm)6-18
No 200
(75 mm)2-8
Suggested Blend
Gradation
PCA suggested
limits
045 Power
curve
- 23 -
Select a mid-range cement content
(eg 12 or 450 pcy)
Perform a modified Proctor test (ASTM
D1557)
Construct moisture-density
relationship curve
Determine Optimum Moisture Content
and Maximum Dry Density
STEP 2 DETERMINE OPTIMUM MC amp MAX DENSITY
Modified Proctor
ASTM D1557
MOISTURE-DENSITY RELATIONSHIP
140
141
142
143
144
2 3 4 5 6 7 8
Dry
De
nsit
y (l
b
cf)
Moisture Content
Maximum density
Optimum moisture
- 26 -
COMPACTION VERY IMPORTANT
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 19 -
SOIL COMPACTION METHOD
Most common method used in the US 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
(ASTM D1557)
3) Determine cementitious content
- 20 -
STEP 1 AGGREGATE SELECTION
Aggregate selection very important
85 of mix by volume
Responsible for mix workability
segregation amp ease of consolidation
Quality of aggregates should meet
ASTM C33
- 21 -
STEP 1 AGGREGATE SELECTION
Nominal Maximum Size Aggregate
ndash Most projects 58rdquo to 34rdquo
ndash As small as 12rdquo for tighter surface and reduced
segregation
ndash 1-12rdquo may be used for non-wearing courses or
where surface appearance is not critical
Plasticity Index (PI) lt 5
Multiple aggregate piles
Consider availability when preparing specs
(during design phase)
- 22 -
STEP 1 AGGREGATE SELECTION
0
10
20
30
40
50
60
70
80
90
100
Pe
rce
nt
Pa
sin
g
Sieve Number
RCCP Gradation Band
045 Power 34 MS Suggested Lower Limit Suggested Upper Limit
200100 416 38 12 34 1
5030 8
Size NumberPercent
Passing
1-in
(25 mm)100
34-in
(19mm)90-100
12-in
(125 mm)70-90
38-in
(95 mm)60-85
No 4
(475 mm)40-65
No 16
(118 mm)20-40
No 100
(150 mm)6-18
No 200
(75 mm)2-8
Suggested Blend
Gradation
PCA suggested
limits
045 Power
curve
- 23 -
Select a mid-range cement content
(eg 12 or 450 pcy)
Perform a modified Proctor test (ASTM
D1557)
Construct moisture-density
relationship curve
Determine Optimum Moisture Content
and Maximum Dry Density
STEP 2 DETERMINE OPTIMUM MC amp MAX DENSITY
Modified Proctor
ASTM D1557
MOISTURE-DENSITY RELATIONSHIP
140
141
142
143
144
2 3 4 5 6 7 8
Dry
De
nsit
y (l
b
cf)
Moisture Content
Maximum density
Optimum moisture
- 26 -
COMPACTION VERY IMPORTANT
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 20 -
STEP 1 AGGREGATE SELECTION
Aggregate selection very important
85 of mix by volume
Responsible for mix workability
segregation amp ease of consolidation
Quality of aggregates should meet
ASTM C33
- 21 -
STEP 1 AGGREGATE SELECTION
Nominal Maximum Size Aggregate
ndash Most projects 58rdquo to 34rdquo
ndash As small as 12rdquo for tighter surface and reduced
segregation
ndash 1-12rdquo may be used for non-wearing courses or
where surface appearance is not critical
Plasticity Index (PI) lt 5
Multiple aggregate piles
Consider availability when preparing specs
(during design phase)
- 22 -
STEP 1 AGGREGATE SELECTION
0
10
20
30
40
50
60
70
80
90
100
Pe
rce
nt
Pa
sin
g
Sieve Number
RCCP Gradation Band
045 Power 34 MS Suggested Lower Limit Suggested Upper Limit
200100 416 38 12 34 1
5030 8
Size NumberPercent
Passing
1-in
(25 mm)100
34-in
(19mm)90-100
12-in
(125 mm)70-90
38-in
(95 mm)60-85
No 4
(475 mm)40-65
No 16
(118 mm)20-40
No 100
(150 mm)6-18
No 200
(75 mm)2-8
Suggested Blend
Gradation
PCA suggested
limits
045 Power
curve
- 23 -
Select a mid-range cement content
(eg 12 or 450 pcy)
Perform a modified Proctor test (ASTM
D1557)
Construct moisture-density
relationship curve
Determine Optimum Moisture Content
and Maximum Dry Density
STEP 2 DETERMINE OPTIMUM MC amp MAX DENSITY
Modified Proctor
ASTM D1557
MOISTURE-DENSITY RELATIONSHIP
140
141
142
143
144
2 3 4 5 6 7 8
Dry
De
nsit
y (l
b
cf)
Moisture Content
Maximum density
Optimum moisture
- 26 -
COMPACTION VERY IMPORTANT
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 21 -
STEP 1 AGGREGATE SELECTION
Nominal Maximum Size Aggregate
ndash Most projects 58rdquo to 34rdquo
ndash As small as 12rdquo for tighter surface and reduced
segregation
ndash 1-12rdquo may be used for non-wearing courses or
where surface appearance is not critical
Plasticity Index (PI) lt 5
Multiple aggregate piles
Consider availability when preparing specs
(during design phase)
- 22 -
STEP 1 AGGREGATE SELECTION
0
10
20
30
40
50
60
70
80
90
100
Pe
rce
nt
Pa
sin
g
Sieve Number
RCCP Gradation Band
045 Power 34 MS Suggested Lower Limit Suggested Upper Limit
200100 416 38 12 34 1
5030 8
Size NumberPercent
Passing
1-in
(25 mm)100
34-in
(19mm)90-100
12-in
(125 mm)70-90
38-in
(95 mm)60-85
No 4
(475 mm)40-65
No 16
(118 mm)20-40
No 100
(150 mm)6-18
No 200
(75 mm)2-8
Suggested Blend
Gradation
PCA suggested
limits
045 Power
curve
- 23 -
Select a mid-range cement content
(eg 12 or 450 pcy)
Perform a modified Proctor test (ASTM
D1557)
Construct moisture-density
relationship curve
Determine Optimum Moisture Content
and Maximum Dry Density
STEP 2 DETERMINE OPTIMUM MC amp MAX DENSITY
Modified Proctor
ASTM D1557
MOISTURE-DENSITY RELATIONSHIP
140
141
142
143
144
2 3 4 5 6 7 8
Dry
De
nsit
y (l
b
cf)
Moisture Content
Maximum density
Optimum moisture
- 26 -
COMPACTION VERY IMPORTANT
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 22 -
STEP 1 AGGREGATE SELECTION
0
10
20
30
40
50
60
70
80
90
100
Pe
rce
nt
Pa
sin
g
Sieve Number
RCCP Gradation Band
045 Power 34 MS Suggested Lower Limit Suggested Upper Limit
200100 416 38 12 34 1
5030 8
Size NumberPercent
Passing
1-in
(25 mm)100
34-in
(19mm)90-100
12-in
(125 mm)70-90
38-in
(95 mm)60-85
No 4
(475 mm)40-65
No 16
(118 mm)20-40
No 100
(150 mm)6-18
No 200
(75 mm)2-8
Suggested Blend
Gradation
PCA suggested
limits
045 Power
curve
- 23 -
Select a mid-range cement content
(eg 12 or 450 pcy)
Perform a modified Proctor test (ASTM
D1557)
Construct moisture-density
relationship curve
Determine Optimum Moisture Content
and Maximum Dry Density
STEP 2 DETERMINE OPTIMUM MC amp MAX DENSITY
Modified Proctor
ASTM D1557
MOISTURE-DENSITY RELATIONSHIP
140
141
142
143
144
2 3 4 5 6 7 8
Dry
De
nsit
y (l
b
cf)
Moisture Content
Maximum density
Optimum moisture
- 26 -
COMPACTION VERY IMPORTANT
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 23 -
Select a mid-range cement content
(eg 12 or 450 pcy)
Perform a modified Proctor test (ASTM
D1557)
Construct moisture-density
relationship curve
Determine Optimum Moisture Content
and Maximum Dry Density
STEP 2 DETERMINE OPTIMUM MC amp MAX DENSITY
Modified Proctor
ASTM D1557
MOISTURE-DENSITY RELATIONSHIP
140
141
142
143
144
2 3 4 5 6 7 8
Dry
De
nsit
y (l
b
cf)
Moisture Content
Maximum density
Optimum moisture
- 26 -
COMPACTION VERY IMPORTANT
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
MOISTURE-DENSITY RELATIONSHIP
140
141
142
143
144
2 3 4 5 6 7 8
Dry
De
nsit
y (l
b
cf)
Moisture Content
Maximum density
Optimum moisture
- 26 -
COMPACTION VERY IMPORTANT
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 26 -
COMPACTION VERY IMPORTANT
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 27 -
STEP 3 DETERMINE CEMENTITIOUS CONTENT
Make and test compressive strength cylinders
ndash Maintain percent optimum moisture content (use OMC determined
in Step 2)
ndash Use varying cement contents eg 10 (370 pcy) 12 (450 pcy)
amp 14 (530 pcy)
ndash Mold three cylinders for each cement content using ASTM C1435
procedure
Select cement content which yields appropriate strength
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 28 -
STRENGTH TESTING
Fabricating cylinders
with 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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
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 (pcy)
330 370 410 450 490 530 570
480 pcy
STEP 3 DETERMINE CEMENTITIOUS CONTENT
frsquoc
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 30 -
FREEZE-THAW DURABILITY
Although not air-entrained field performance very good
ndash Reference Long-Term Performance of RCC Pavements RP366
Most distress along joints
Minor surface paste (18rdquo) erodes then stabilizes
RCC results variable under ASTM C666 (F-T) and C672 (deicingscaling)
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 C67) possibly more appropriate
DO NOT use deicing agents on RCC surface for at least 30-days after completion
BN Intermodal Yard CO
Built 1985 Photo 2009Fort Drum NY
Built 1988 Photo 2013
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 31 -
DRY BATCH CONCRETE PLANT
Readily available
Good for small jobs
2-step process
ndash Feeds transit mixers
ndash Discharge into dumps
Mix 50 - 60 capacity
Low production
Dedicated trucks
Segregation concern
Intermittent cleaning required
Portable pugmill mixers
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 32 -
CONCRETE BATCH PLANT
Highly accurate proportioning
Local availability
Smaller output capacity
Longer mix times than conventional
concrete
More cleaning with drum mixer
Dedicated production
Horizontal shaft spiral blade mixer
very efficient
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 33 -
CONTINUOUS PUGMILL
High-volume applications
100 to 250+ cyhr
Excellent mixing efficiency
Mobile erected on site
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 34 -
TRANSPORTING
Rear dump trucks normally
used
Minimizes transport time
Covers required for long hauls
or in hotwindy conditions
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 35 -
Moisture Content
bull Moisture content is critical
bull Check at plant
bull +- 05 of optimum
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 36 -
WATCH FOR SEGREGATION
Load in multiple piles to avoid segregation
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 37 -
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
RESOURCE MATERIAL
Introduction
Applications
Properties
Mixture Proportioning
Structural Design
Production
Construction
Troubleshooting
wwwcementorgbookstore
SN298
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
RCC TRAINING MODULES
Based on RCC Guide
Six One-Hour Modules
ndash Introduction amp Uses
ndash Properties
ndash Mixture Proportioning
ndash Structural Design
ndash Production
ndash Construction
Free
Available at wwwnhifhwadotgov
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 40 -
ACPA ndash NATIONAL RCC EXPLORER
rccacpaorg
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 41 -
AGENDA
bull Introduction What is Roller Compacted Concrete and What Are Its Benefits (Wayne Adaska)
bull RCC Mix Design amp Production Process (Wayne Adaska)
bull RCC Placement Process and Case Studies (Corey Zollinger)
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 42 -
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 43 -
THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES amp EQUIPMENT NEEDED TO BE SUCCESSFUL
Natural RCC Diamond Ground RCC Asphalt
bull Ports
bull Distribution centers
bull Industrial yards
bull Residential roads
bull Parking lots
bull Collector Arterial local roads
bull Highway Shoulders
bull State routes
bull Any pavement type
bull Lowest Cost
bull Most sensitive to contractor
skill level
bull Least smooth
bull Ugly surface appearance
bull Medium cost increase
bull Increased construction time
bull Improved smoothness skid
resistance
bull Reduced noise
bull Highest cost
bull Increased construction time
bull Least sensitive to contractor
skill level
bull Improved smoothness skid
resistance
Ap
pli
ca
tio
ns
Fa
cto
rs
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 44 -
FACTORS TO CONSIDER FOR PAVINGConsistent Mix Delivery to Paver
bull 10 Wheel dump trucks - Cover loads
bull Keep trucks clean
bull Plan trucking route (traffic truck staging)
bull Avoid segregation in truck loading unloading
bull Avoid end of load segregation
bull Consider using material transfer machine amp
insert hopper
bull Balance speed of paver with mix delivery
bull Use paving calculator
bull Keep paver moving (material transfer machine)
bull Keep head of material constant in hopper and screed
bull Keep augers feeding material consistent
bull Use grade control devices (string big ski etc)
bull Donrsquot pave over standing water
Mix Delivery Paver Operation
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 45 -
RCC IS PAVED WITH ASPHALT EQUIPMENTAchieving Density amp Smoothness is Critical
bull Standard paver (80 to 85 initial density)
bull Available in all markets
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 6rdquo
bull May require multiple lift paving
bull Impossible to pave adjacent lanes
bull Increased roll down to achieve density (grade
control problems)
bull Easier to fix segregated areas before
compaction
bull High density screed (Vogele or ABG Titan)
bull High initial density (gt 90)
bull Availability is increasing but still limited
bull Smoother surface with higher initial density
bull Less roll down to achieve density
bull High-production (6 to 8 ftmin)
bull Lift thick range 4rdquo to 9rdquo
bull Adjacent lanes easily paved
bull Recommended
Standard Paver HIGH DENSITY PAVER
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 46 -
THICK RCC IS PLACED WITH HIGH DENSITY ASPHALT PAVERSAchieving Density amp Smoothness is Critical
bull High density screed (Vogele or ABG Titan)
bull High initial density from paver (90 - 96)
bull Smoother surface due to higher initial density
bull Less ldquoroll downrdquo to achieve final density
bull High-production (6 to 8 ftmin)
bull 10 to 30 ft width
bull Lift thick range 4rdquo to 9rdquo
High Density Paver
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 47 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH
bull Initial 10 - 12 ton static amp vibratory roller
bull Thinner lifts may allow smaller roller
bull Establish roll pattern (check density a lot)
bull Adjust roll pattern based on moisture content (visual
observation and lab measurements to confirm)
bull Compact to 98 of modified proctor (wet density)
bull Adjust moisture content if needed ndash impacts smoothness
bull Finer mixes achieve density easier
bull Combination dual steel or rubber tired
bull Maximum weight - 6 short ton
bull Remove roller marks
bull Once completed keep roller off of the area
Initial Compaction Finish Rolling
Fairforest Way
Greenville SCGrape Creek Road ndash San Angelo TX
Fairforest Way
Greenville SC
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 48 -
bull Need high density paver
bull Attach shoe to screed
bull Maximum angle 15o
bull Use plate tamper to improve edge durability
bull No saw cutting required
bull Pave adjacent lane next day
bull Debatable performance possible shear crack
bull Pave for 50 minutes then move back to
beginning and match original lane
bull Do not compact original lane within 2 ft
of edge until adjacent lane is paved
bull Recommend a longitudinal saw cut
bull Use small loader to create fresh vertical
transverse joint
bull Move quickly ndash keep moist
bull Coordination is key avoid breakdowns
Angular Cold Joint Fresh (Hot) Joints
bull Pave width of lane
bull Saw cut full depth early next morning
bull Remove with blade amp loader
bull Expect waste
bull Reduce waste with paver shoe amp plate tamper
bull Pave adjacent lane and match thickness of existing lane
bull Good performance limited load transfer
Vertical Cold Joint
LONGITUDINAL JOINTS CAN BE BUILT 3 DIFFERENT WAYS
2 ft
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 49 -
MANHOLES amp CURBS ARE EASILY INCORPORATED
bull Traditional curb amp gutter placed before RCC
bull Serves as compaction aid
bull Joint may need to be sealed
bull Alternatively ribbon curb can be placed
bull Drill amp grout rebar into cold RCC
bull Place ribbon curb afterwards
bull Plywood plate is placed on top of hole before RCC is placed
bull After paving two methods are available
bull Dig RCC immediately while fresh place manhole and re - compact material with hand tampers
bull Saw cut hardened RCC place manhole tie in with conventional concrete
Curb amp Gutter Manholes Inlets
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 50 -
QC QA PROCESS INCLUDES TESTING FOR DENSITY MOISTURE CONTENT amp COMPRESSIVE STRENGTH
bull Tested with nuclear gage in direct mode
bull Test density behind paver amp after roller to establish rolling patterns to achieve density
bull Achieve 98 of modified proctor wet density
bull Nuclear gage gives general moisture fluctuation indication - Calibrate with oven dried moisture
bull Oven dried is most accurate
bull Cylinders prepared with vibratory hammer according to ASTM C1435
bull 3 to 4 cylinders per set
bull Strength timing often depends on traffic opening (1 3 7 28 days)
bull Cores can be obtained where density is not being achieved
Compressive StrengthMoisture amp Density
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 51 -
RCC PAVEMENTS NEED TO BE CURED amp SAW CUT FOR PERFORMANCE amp AESTHETIC BENEFITS
bull Applied at same rate or slightly higher than conventional concrete
bull Ensure uniformity with application process
bull Apply as soon as possible behind roller operation
bull Recommend WR Meadows 1200 to 1600
bull Ensures durable surface
Curing Saw Cut amp Fill Joints
bull More aesthetically pleasing
bull Early entry saw very effective shortly following placement
bull Recommend sawing within 2 - 6 hours to avoid uncontrolled cracking
bull Depth 1rdquo to 2rdquo
bull Spacing Maximum 36 times thickness
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 52 -
Grape Creek RoadSan Angelo TX
bull Owner City of San Angelo
bull Use Type Collector Arterial
bull Year Built 2011
bull Quantity 2550 CY
Project
Information
bull Thickness 6rdquo RCC 8rdquo Stabilized Subgrade (Lime amp Cement)
bull Diamond Ground Surface
bull First RCC pavement in West Texas
Additional
Details
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 53 -
GRAPE CREEK ROADIRI Measurements (Average)
0
10
20
30
40
50
60
70
80
90
100
0 01 02 03 04 05 06 07 08
IRI (
inm
ile)
Distance
Southbound
Northbound
Overall AVG 784
Overall Max 941
Overall Min 541
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 54 -
LAKE VIEW HEROES DRIVE
SAN ANGELO TX
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 55 -
LAKE VIEW HEROES DRIVE IRI Measurements (Average)
0
20
40
60
80
100
120
0 01 02 03 04 05 06 07 08 09
IRI (
inm
ile)
Distance
IRI - West - R
IRI - West - L
IRI - East - R
IRI - East - L
Overall AVG 637
Overall Max 1167
Overall Min 317
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 56 -
LAMESA DRIVE
MIDLAND TX
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 57 -
OVER THE PAST 10 YEARS DOTrsquoS HAVE PAVED SHOULDERS amp SURFACE ROADS USING RCC
I-85 Interchange ndash Lagrange GA SR 6 ndash Powder Springs GA
US 78 ndash Aiken SC
I 285 ndash Atlanta GA
I 385 - Greenville SC I 75 ndash Tift Cook GA
South Carolina DOT Projects
US 21 Greystone
Blvd
US 25 SC 5
New State
Road
S Beltline
Blvd
SC 9
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 58 -
bull Owner South Carolina DOT
bull Use Type US Highway
bull Year Built 2009
bull Thickness Milled 10rdquo asphalt
Placed 10rdquo RCC
bull Traffic 6000 ADT 4 lanes
bull Speed 45 mph
Pavement
Design
Information
bull Replaced 27500 SY in 15 days
bull Placed 10rdquo RCC in 1 lift
bull All milled areas were paved within same day
bull Maintained 1 lane open in each direction
bull Transverse Joints 20 ft early entry saw cut within 3 hours
bull Traffic re-opened within 24 hours
Additional
Details
Richland Ave (US 78)Aiken SC - 2009
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 59 -
RICHLAND AV (US 78) AIKEN SC
Completed Project
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 60 -
Village of Streamwood StreetsStreamwood Il
bull Owner City of Streamwood
bull Use Type Residential
bull Year Built 2011 2013
bull Quantity 1000 CY each
Project
Information
bull Thickness 2rdquo HMAC 6rdquo RCC
bull City forces completed all work
Additional
Details
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 61 -
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 62 -
ROLLER COMPACTED CONCRETE HAS BEEN USED ON MANY SUBDIVISION STREETS IN OHIO SINCE 2001
bull Longwood
bull Marble Cliff Crossing
bull Quarry Pointe
bull Alkire Place
bull Crawford Farms 6-1
bull Creekstone
bull Prestwick Green
bull The Preserves
bull Kensington
bull Grant Run
bull Taylor Glen Section 1
bull Longview
bull Park of Waggoner
bull Quarry Park 1
bull Woods of Reynoldsburg
bull Villages of Hilliard Green
bull Cumberland Trails
bull Watkins Grove
bull Sunbury Estates
bull Abbie Trails
bull Blendon Reserve
bull Cedar Run
bull Chestnut Estates
bull Creekstone 2-4
bull Haley Hollow
Short List of Developments with RCC in
Columbus OH Area
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 63 -
bull Owner Lowersquos
bull Use Type Distribution Center
bull Year Built 2012
bull Size 69 Acres
bull Volume 65000 CY
Project
Information
bull Thickness 7rdquo RCC 6rdquo Aggregate Base
bull Traffic 400 Trucks day
bull Paved 30 ft wide 150 to 180 CY hour
bull RCC paving completed in 2 months 11 days (Calendar)
bull Saved $35 M versus asphalt with concrete dolly strips
Additional
Details
LOWErsquoS DISTRIBUTION CENTERRome GA - 2012
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 64 -
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 65 -
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 66 -Standard Equipment Companyndash Houston TX - 2014
Heavy Industrial
Exist 14 ndash 18rdquo CTB
Issues Water
ponding mud dust
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 67 -Standard Equipment Companyndash Houston TX - 2014
Solution
bull Mill 14rdquo Existing
bull Cement treat remaining
base subgrade 8rdquo
bull 14rdquo RCC
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 68 -
bull Owner Southern Company
bull Use Type Distribution Center
bull Year Built 2012
bull Size 363000 SY
bull Volume 51500 CY
Project
Information
bull Thickness 4 6 7 10 amp 18rdquo RCC
bull Pavement Types Parking lot Laydown areas Haul Roads Industrial area
bull Converted 2rdquo AC 6rdquo Ag Base to 4rdquo RCC 6rdquoSoil cement
bull Reduced lighting by 50
bull Saved owner 25
Additional
Details
PLANT VOGTLE NUCLEAR PLANTGA ndash 2011 to 2013
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 69 -
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 70 -
YUMA EAST WETLANDS HIKE TRAILYuma AZ
bull Owner City of Yuma
bull Use Type Trail
bull Year Built 2013
bull Thickness 5rdquo RCC Compacted Subgrade
bull Quantity 1700 CY
Pavement
Design
Information
bull City Park environmentally
sensitive area
bull Did not want Asphalt due to
hydrocarbons
bull Lacked funds for conventional
concrete
bull RCC made it feasible
Additional
Details
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 71 -
bull Owner Yuma Truck Driving School
bull Use Type Truck Parking
bull Year Built 2013
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
Yuma Truck Driving SchoolYuma AZ - 2013
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 72 -
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 73 -
bull Owner Yuma County Water Users
bull Use Type Roadway
bull Year Built 2014
bull Size 6280 SY
bull Volume 1215 CY
Project
Information
bull Thickness 7rdquo RCC Compacted Subgrade
bull Traffic 20 Trucks day
bull Paved 16 ft wide
bull RCC paving completed in 3 days
bull Used 90 passing frac12rdquo Sieve
bull Owner knew that asphalt wouldnrsquot hold up to the turning movements of the trucks
Additional
Details
YUMA COUNTY WATER USERSYuma AZ - 2014
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
- 74 -
Questions
Wayne Adaska PE
wadaskacementorg
847-972-9056
Corey J Zollinger PE
coreyjzollingercemexcom
713-722-6084
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