Name – Pratyaksh Bhagat

Entry no. – 21bce038

Branch – Civil Department
 Presentation on
Roller Compacted Concrete
Roller Compacted Concrete
Roller-compacted concrete (RCC) is a special blend of concrete that has essentially the same ingredients
as conventional concrete but in different ratios, and increasingly with partial substitution of fly ash for
Portland cement. It's placed with conventional or high-density asphalt paving equipment or high-density
asphalt paving equipment, then compacted with rollers.
RCC got its start in the Seventies, when the Canadian logging industry switched to
environmentally cleaner, land-based log-sorting methods. The industry needed a strong
pavement to stand up to massive loads and specialized equipment. Yet economy was
equally important: log-sorting yards can span 40 acres or more. RCC met this challenge
and has since expanded to other heavy-duty applications.

Today, RCC is used when strength,

durability, and economy are primary needs:
Port, intermodal, and military facilities;
parking, storage, and staging areas;
streets, intersections, and low-speed roads.
Unique Mix, Unique Construction

RCC owes much of its economy to high-volume,

high-speed construction methods. Large capacity mixers
set the pace. Normally, RCC is blended in
continuous-mixing pugmills at or near the construction site.
These high-output pugmills have the mixing efficiency
needed to evenly disperse the relatively small amount of
water used.

Dump trucks transport the RCC and discharge it into an

asphalt paver, which places the material in layers up to
10-inches thick and 42-feet wide.
Roller Compacted Concrete Specifications/ Properties

1. Consistency of RCC – it should be of the consistency of damp gravel.

2. Slump – slump of concrete mixture should be zero slump.

3. Water content –The water content is chosen based on the optimum moisture content
(OMC) at maximum dry density (MDD).

4. Aggregate – The aggregate used should typically be a combination of larger fine

aggregate content and coarse aggregates with a maximum size of 20mm.

5. Thickness – it should be placed in layers or “lifts” of 150 to 250 mm thickness. The

thickness can vary depending on the specific project requirements.

6. Use of supplementary cementing materials – High volume fly ash has been used in some
cases up to 60% by the weight of cement. The cement content can range from 60 to 360
kg/m3.
 CONCRETE PERFORMANCE

High flexural strength Supports heavy, repetitive loads without

(500 to 1,000 psi) failure and spans localized soft subgrade
areas, which reduces maintenance costs
and down time.

High compressive strength (4,000 to 10,000 Withstands high concentrated loads and
psi) impacts from heavy industrial, military, and
mining applications.

High shear strength

Eliminates rutting and subsequent repairs.

Aggregate interlock
Provides high shear resistance at joints and
uncontrolled cracks to prevent vertical
displacement or faulting.
 CONCRETE PERFORMANCE

No forms or finishing
Speeds construction, reduces cost,
minimizes labor.

No steel reinforcing or dowels

Speeds and simplifies construction,
reduces costs.

Low water content, low water/cement ratio Increases strength, reduces permeability,
and enhances durability and resistance to
chemical attack.

Hard, durable, light-colored surface Resists abrasion, eliminates need for

surface course and reduces cost. The light
color reduces lighting requirements for
parking and storage areas.
Roller Compacted Concrete features

1. Consistency of RCC – it should be of the consistency of damp gravel.

2. Slump – slump of concrete mixture should be zero slump.

3. Water content –The water content is chosen based on the optimum moisture content
(OMC) at maximum dry density (MDD).

4. Aggregate – The aggregate used should typically be a combination of larger fine

aggregate content and coarse aggregates with a maximum size of 20mm.

5. Thickness – it should be placed in layers or “lifts” of 150 to 250 mm thickness. The

thickness can vary depending on the specific project requirements.

6. Use of supplementary cementing materials – High volume fly ash has been used in some
cases up to 60% by the weight of cement. The cement content can range from 60 to 360
kg/m3.
Application of Roller Compacted Concrete

3. Other applications:
● Levees: RCC’s ability to resist water and erosion makes it a popular choice for
building levees.

● Industrial pavements: RCC’s durability and low maintenance make it ideal for use in
ports, airports, and heavy-duty yards.

● Road construction: RCC is used for building roads and highways, as well as airport
runways, taxiways, and aprons.

● Mining: RCC can handle heavy loads and traffic, making it useful for constructing
mining infrastructure such as haul roads and tailing dams.

● Landfill: RCC is used for constructing landfill liners and caps, as it can provide a
strong barrier against leachate and gases.
Application of Roller Compacted Concrete

1. Construction of Dams: As dams need to withstand high pressures and loads,

durable concrete of sufficient strength is used in construction.

Because of the below points, RCC is very suitable to use in dams.

● Economical mix of RCCs

● RCC’s strength and durability
● Limited heat of hydration

2. Laying of concrete pavements: Roller compacted concrete (RCC) is particularly

suitable for concrete pavement construction because of below reasons
● RCC offers good aggregate interlocking and rapid construction in a short amount of
time.
● RCC has a fast rate of strength development, allowing for early opening to traffic.
Other applications of RCC

● RCC is used in various projects such as

● Airports.
● Industrial and military facilities.
● Dams construction.
● Parking and storage facilities.
● Ports.
● Power plants and other industrial facilities.
● Rehabilitation of existing dams.
● Reservoir liners.
● Streets & highways, intersections, shoulders, turn lanes, bike paths.
etc.
Roller Compacted Concrete Procedure

1. Mix proportion

Mix proportioning of RCC differs from conventional concrete for its drier consistency.

The factors affecting mix proportioning are as below;

● Cement and cementing material content between 12 to 15% of dry materials

● High usage of pozzolans
● Aggregate content between 75 to 85% of the volume of the RCC mix
● Very low water content
● Use of various admixtures

The mix should be dry enough to be placed and compacted with heavy rollers, but wet
enough to achieve proper compaction.
 Typical proportion of RCC

Water-binder ratio 0.440

Cement 0.78

Fly Ash 0.22

Fine aggregate 1.78

Coarse aggregate (mm) (10 - 4.75) 1.33

(20 - 10) 2.0

Water content (kg/m3) 160

Roller Compacted Concrete Procedure

2. Transport

The dry and lean mix is transported in dump trucks or pavers or loaders to the
construction site.
Roller Compacted Concrete Procedure

3. Placement

The dry mix is placed in the area where the RCC is to be constructed.
It is then spread out evenly over the area with help of bulldozers or conventional asphalt
spreaders or graders.
The layer placed is 200 to 300 mm thick and is called “lift”
Roller Compacted Concrete Procedure

3. Placement
Roller Compacted Concrete Procedure

4. Compaction

Heavy rollers, similar to those used for asphalt paving, are used to compact the RCC.
The first and second compaction of RCC is done using a vibrating roller.
The first compaction is done without vibration, while the second compaction is done with
vibration.
The rollers compress the RCC and bring the particles of the mix closer together.
Roller Compacted Concrete Procedure

4. Compaction
Roller Compacted Concrete Procedure

6. Finishing

RCC is typically placed and compacted to a smooth finish, but it can be textured with a
broom or other tool.
Benefits of RCC

● Roller compacted concrete provides great strength

● Roller compacted concrete no need to use forms

● In this roller-compacted concrete rebar is not required

● Roller compacted concrete is high volume placement

● It can be used as a roadway after only 24 hours of being placed

● Will not be affected by oil spills, fuels and/or hydraulic fluids

● Can withstand high temperatures

Advantages of Roller Compacted Concrete

● This roller compacted concrete is cost-effective and fast construction.Transportation

costs, placement, and compaction of concrete are minimized, as a result, the
concrete will be handled by dump vehicles; spread by the bulldozers and
compressed by vibration rollers.

● Roller compacted concrete requires minimal maintenance.

● The cost of formwork is minimized or eliminated due to the layer placement method.

● Roller compacted concrete does not deform under heavy concentric loads.

● There is no concern about the release of high heat during the drying of concrete.

● Small construction crew

Disadvantages of Roller Compacted Concrete

● Smoothness is difficult to achieve.

● Skill person required.

● In roller compacted concrete dams, the drainage gallery often increases

construction time and increases costs because the earth fill method being used
does not easily accommodate such a construction.

● Situations, where Roller Compacted Concrete may not be appropriate, is when

aggregate material is not reasonably available, the foundation rock is of poor quality
or not close to the surface, or where foundation conditions can lead to excessive
differential settlement.

● Dams constructed or repaired with roller-compacted concrete may suffer from water
seepage. That is why water stoppage layers shall be considered
RCC and Dam Construction

Evolution of Use of Roller Compacted Concrete in Dams

● The first RCC dam construction was started in

Japan in 1978 and completed in 1980.

● Afterward, Several RCC dams were constructed,

and by the end of 1985, 7 RCC dams had been
completed.

● With this RCC construction technology became

widely accepted.

● Between 1985 and 1992, 96 RCC dams were

built in 17 countries, including the US, Japan,
and Spain.
RCC and Dam Construction
RCC and Dam Construction
Roller Compacted Concrete Pavement (RCCP) Construction Process

RCC is emerging as a common base for conventional highway and street pavements due to its
advantages as a comparatively low-cost and durable paving material.

● RCC is mixed in a continuous mixing pug mill or normal mixer used for soil-cement treated
base or asphalt concrete construction.

● The pavement is constructed in lifts of 150-200 mm for a thickness greater than 400 mm.

● The elapse time between lifts is of 30 minutes to 2 hours.

● A layer of asphalt may be used to cover the surface if a smooth pavement surface is not
obtained.

● Curing of RCCP is accomplished by keeping the surface of the pavement wet for seven
days, commonly by using water spray or fine mist.
Roller Compacted Concrete Pavement (RCCP) Construction Process

Some Disadvantages of RCCP

● The total thickness of an RCCP structure is much less than an asphalt/gravel

pavement of the same load-carrying capacity.

● A higher volume of mineral binders can be used than that used in vibrated concrete
pavements because of the stability of the mineral structure.
Roller Compacted Concrete Pavement (RCCP) in India
In India, RCC has been employed in large-scale projects.
RCC was used in the construction of
● Delhi-Mathura Road construction
● Pune-Mumbai expressway construction

Concreting Specifications for the above projects:

● Grade of Concrete: M10
● Thickness of pavement layer: 15 cm
● Compaction equipment: Vibratory rollers

Afterward, a layer of Pavement Quality Concrete (PQC) was laid on top with specifications:
● Concrete grade (for pavement layer): M40
● Thickness of pavement layer: 35 cm
● Both projects utilized Roller Compacted Concrete as base concrete.
SUMMARY
Roller compacted concrete (RCC) is a type of concrete that is characterized by its dry, stiff consistency and its
ability to be placed and compacted using heavy rollers.

Roller Compacted Concrete Specifications

● Consistency of RCC same as that of damp gravel.
● Slump of RCC = 0

Advantages of Roller-Compacted Concrete

● It is 1/3rd cheaper than conventional concrete because of,
● Economical mix
● Lesser formwork
● Use of the same equipment as used in earthen dam construction
● Speedy construction
It has a low heat of hydration production during construction.

Disadvantages of Roller-Compacted Concrete

The major disadvantage of RCC is insufficient bonding between fresh and old layers of concrete forming cold
joints.
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