morgan corp.

Roller-Compacted Concrete
Pavements

Fares Abdo, PE
Director of Technical Services
fabdo@morgan-corp.com Groundbreaking Solutions
Morgan Corp. Area of Operations

Offices
 Spartanburg, SC
 Charlotte, NC
 Savannah, GA

Area of operations
What Services Do We Offer?
 Heavy industrial,
commercial and highway
sitework
 Utilities
What Services Do We Offer?
 Roller-compacted
concrete pavements
 Roller-compacted
concrete dams
What Services Do We Offer?
 Cement-treated
pavement bases
 Full-depth reclamation
of asphalt pavements
Today’s Topic – RCC Pavements
 Introduction
 Benefits
 Applications
 Construction
 Case Studies
Reference

Guide for Roller-

Compacted
Concrete
Pavements
www.cement.org/bookstore
PCA Code: SN298
Introduction
Introduction

■ Definition: “Roller-Compacted Concrete (RCC) is a no-

slump concrete that is compacted by vibratory rollers.”
■ Zero slump (consistency of dense-graded aggregate)
■ No forms needed
■ No reinforcing steel
■ No finishing
■ Consolidated with vibratory rollers
After curing, RCC properties are similar to PCC
Benefits of RCC Paving

■ Fast construction with minimum labor

■ Economical
■ High load carrying ability
■ Eliminates rutting
■ Early strength gain
■ Durable
■ Low maintenance
■ Light surface reduces lighting requirements
Project Considerations
■ Project size
■ Site geometry
■ Loading
characteristics
■ End use
■ Client
expectations
RCC Pavements Applications
Log Sort Yards

Vancouver Island, BC, 1978

 Military facilities

Ft. Carson, CO, 2008

Ft. Lewis, WA,1986

Ft. Drum, NY, 1990

 Parking Areas

134 acre parking facility

at Saturn plant, TN, 1988 BMW, SC, 2009

Plant Vogtle, GA, 2011

Employee Trailer

Truck

Ohio Turnpike Service Plaza,

2010
Honda facility, AL, 2001
Intermodal and Port Facilities
Why Intermodal and Port Facilities
Should Use RCC?
 Very cost effective rigid
pavement
 Speed of Construction so
areas may be utilized
quickly
 Load carrying abilities
 Low maintenance cost
Warehouses and Distribution Centers

Distribution Center, Spartanburg, SC

Streets and Roads
Residential street
Columbus, OH

US-78, Aiken, SC
City street Aug 2009
Spartanburg, SC
Surface Appearance
 Owner’s
expectations?
 Cost?
Materials
Materials
 Aggregates
 Cementitious
materials
 Water
 Chemical admixtures
(if used)
 Curing compound
 Aggregates Blend Gradation

Suggested Blend
Gradation
RCCP Gradation Band
Percent
Size Number 0.45 Power, 3/4" MS Suggested Lower Limit Suggested Upper Limit
Passing
1-in 100
100
(25 mm)
90
3/4-in
90-100 80
(19mm)
1/2-in 70
70-90
(12.5 mm)
Percent Pasing

3/8-in 60
(9.5 mm)
60-85 0.45 Power
50
No. 4 curve
40-65 40
(4.75 mm)
No. 16
(1.18 mm)
20-40 30 PCA suggested limits
No. 100 20
6-18
(150 m)
10
No. 200
2-8
(75 m) 0
#100 #30 #16 #8 #4 3/8" 1/2" 3/4" 1"
#200 #50 Sieve Number
Engineering Properties

■ Compressive Strength (f’c)

▪ 4,000 to 6,500 psi (up to 10,000 psi have been used)
■ Flexural Strength (MR)
▪ 500 to 1,000 psi
▪ MR = C(f’c)1/2 where C ranges from 8 to 12
■ Modulus of Elasticity
▪ 3.5 to 6 million psi
▪ E = CE(f’c)1/2 where CE = 57,000 (up to 67,000)
RCC Mixture Design

■ Dry enough to
support
vibratory roller
■ Wet enough to
permit adequate
distribution of
paste
Strength Testing
Fabricating cylinders
with vibrating hammer
(ASTM C1435)
Field Density Testing

■ Reference density
■ Modified Proctor
■ Average max. density
■ Max. theoretical
density
■ Field wet density
should not be less
than 98% of Nuclear Gauge
modified Proctor wet ASTM C1040

density
Thickness Design
RCC Thickness Design

■ Follows rigid pavement design

methods
■ Plain, undoweled, unreinforced
concrete pavement
■ PCA RCC-PAVE Program
available at
www.cement.org/pavements
■ Other methods:
■ Street Pave by ACPA
■ PCASE by USACE
■ ACI design tables
Construction
Mixing: Continuous Mix Pugmill

■ 250 to 600
tons/hr
■ Excellent mixing
efficiency
■ Mobile, erected
on site
■ Mobilization
cost
Transporting
Paving Equipment

Material Transfer
Device
Paver
 Placing Equipment

■ High density pavers

■ Vibrating screed
■ High initial density,
90-95%
■ High-volume
placement (capable
of placing 1,000 to
2,000 cubic yards
per shift)
Compaction
■ High density is
critical for
strength and
durability
■ Rubber-tire roller
or rubber coated
steel drum roller
for smooth
surface texture
Joints
■ Transverse crack control
joints (early-entry saws)
■ Construction joints:
■ Fresh or cold longitudinal
joints
■ Cold transverse joints at
end of shifts
■ Horizontal joints
■ Isolation and expansion
joints
■ Expansion joints
Joints
Longitudinal

Transverse
 Curing

■ White-
pigmented
concrete
curing
compounds
■ Apply about
1.5 times the
normal
application
rate
Case Studies
Case Study – Ocean Terminal, GA
Case Study – Ocean Terminal, GA

■ Typical Ocean
Terminal pavement
■ Flexible pavement
■ 10” aggregate base
■ 5” asphalt

■ Purposes of
proposed alternate
■ Provide equal or higher
structural capacity using
RCC and CTB layers
■ No additional cost
Structural Capacity/Predicted
Service Life for Assumed Loadings

 Hot-Mixed Asphalt and RCC equivalent

Structural Numbers

 RCC PAVE software predictions

 PCA PAVE Software predictions

 Pavement Analysis - Equivalent Structural Number Approach
Material SN Coefficient Notations
HMA 0.44 HMA Hot-Mixed asphalt, Binder or Surface Course
RCC 0.5 RCC Roller-Compacted Concrete1
GABC 0.18 GABC Graded Aggregate Base Course
CTB 0.22 CTB Cement-Treated Base2
SN Structural Number

Alternate Section, RCC & CTB (based on

Design Section, HMA& GABC
equivalent SN)
Thickness, In. SN/in. SN/layer Thickness, In. SN/in. SN/layer
HMA 5 0.44 2.20 RCC 6 0.50 3.00
GABC 10 0.18 1.80 CTB 6 0.20 1.20
Total SN 4.00 Total SN 4.20

Footnotes
1. RCC specified compressive strength = 4,000 psi at 28 days.
2. Assume 50% GABC mixed with 50% in-situ soil to make the blended aggregates/soil for CTB. CTB compressive strength target = 300 -
500 psi at 7 days.
Pavement Analysis - Equivalent Structural Number Approach

Asphalt Pavement Roller Compacted Concrete

Design Design

5” HMA 2.22 6” RCC

Concrete 3
10”
Aggregate 1.8 6” Cement 1.2
Base Treated base

Subgrade 0
Subgrade 0

Structural Number= 4.00 Structural Number= 4.20

 RCC PAVE Predictions Using Truck
Loads, RCC with CTB Option, 20 Yr
Roller Compacted Concrete
Design

6” RCC
Concrete
Axle Type Load, lbs Allowable
Repetitions/Day 6” Cement
Treated base
Single Axle Dual Wheel 18,000 Unlimited
Tandem Axle, Dual Wheel 40,000 Unlimited Subgrade
RCC PAVE Predictions Using Straddle Carrier, RCC with
CTB Option, 20 Yr
90
Straddle Carrier
80
Alloowable Daily Repetitions

70

60

50

40

30

20 Single wheel
loading
10

0
4 6 8 10 12
Load per Tire X 1000 lbs
 RCC PAVE Predictions Using Container Handler, RCC
with CTB Option, 20 Yr

100
Container Handler
90
Unlimited repetitions at 9,000 lbs

80
Alloowable Daily Repetitions

70

60

50

40

30

20
Dual-wheel
loading
10

0
8 9 10 11 12 13 14 15 16
Load per Tire X 1000 lbs
PCA PAVE Predictions Using Semi Trailer Trucks, HMA
over GABC Option

■ Purposes of
proposed alternate
■ Provide equal or higher
structural capacity using
12
20 each 20 each RCC and CTB layers

Total Truck Weight: 12k+40k+40k = 92k lbs

■ No additional cost
10 Trucks/day, 5” HMA over 10” GABC, on Sandy Soil

12k+40k+40k = 92k lbs

50 Trucks/day, 5” HMA over 10” GABC, on Sandy Soil

12k+40k+40k = 92k lbs

100 Trucks/day, 5” HMA over 10” GABC, on Sandy Soil

12k+40k+40k = 92k lbs

100 Trucks/day, 6” RCC over 6” CTB, on Sandy Soil

12k+40k+40k = 92k lbs

1000 Trucks/day, 6” RCC over 6” CTB, on Sandy Soil

12k+40k+40k = 92k lbs

Case Study – Ocean Terminal, GA

■ Typical Ocean
Terminal pavement
■ Flexible pavement
■ 10” aggregate base
■ 5” asphalt

■ As- built Section

■ RCC/Cement-Treated Soil Section Structural
Number
■ 9” cement-treated soil
Flexible 4.0
■ 7” RCC
RCC/CTS 5.3
Case Study – Ocean Terminal, GA

33% strength

No additional cost
Case Study – Plant Vogtle, GA
363,000 SY
■ 363,000 SY
■ 4, 6, 10 and 18 inch
pavements
Case Study – Plant Vogtle Parking Lot,
GA
■ Original design
■ 6” aggregate base
Section Structural
■ 2” asphalt Number

■ Proposed alternate Flexible 2.0

RCC/CTS 3.2
■ 6” cement-treated soil
■ 4” RCC
Case Study – Plant Vogtle Parking Lot,
GA

60% strength

25% construction
cost
Case Study – Plant Vogtle Parking Lot,
GA

50% lighting
requirements
Conclusions
■ Why RCC pavements should be considered?
■ RCC Pavements have been in service for more
than 30 years. They continue providing good
service.
■ Owners and engineers are increasingly
choosing RCCP because of its:
■ Speed of construction with minimal labor
■ Cost effectiveness
■ Proven long-term performance (durability)
■ High load carrying capacity without rutting
■ Very low or no maintenance requirements
 morgan corp.

Questions?
Click to edit Master title style

Click to edit Master subtitle

style
Fares Abdo, PE Eric Vannier
Director of Technical Services Business Development
fabdo@morgan-corp.com evannier@morgan-corp.com
Office: 864.433.8800 Office: 912.629.9439
Cell: 704.201.2734 Cell: 912.659.1476
Groundbreaking Solutions
62