SP 171-21

Construction of Joints in Roller

Compacted Dam concrete
by Takeo lisaka

Synopsis : Construction of transverse joints with lateral molds in RCD ( Roller

Compacted Dam) method has been omitted because concrete layers arc casted
continuously. However, transverse joints in dam concrete should be required to
prevent the occurrence of cracking.
In this study, the development of a vibrating machine which can make the
joints was done so that the transverse joints could be constructed in the RCD
concrete. Many kinds of experiments were conducted using this machine with
respect to period and direction of joint, pattern ofjoint material and its injection,
in order to make clear the method for construction ofjoints.
The proposed method is applicable in the actual construction of RCD
concrete, and preferable results arc obtained.

Keywords: Joint fillers; joints (junctures); roller compacted concrete; vibrators

(machines).

445
446 lisaka

Takeo Iisaka is an associate professor of Civil Engineering at Mcijo University,

Nagoya Japan. He is a member of JSCE, JCI and JMS. His research interests
include resin concrete, high performance concrete and repair materials for cracks
in concrete.
Noriyuki Suzuki is a professor of Civil Engineering at Meijo University, Nagoya
Japan. He is a member of JSCE. His research interests include construction
method of roller compacted dam concrete.
Hidctaka Umehara is a professor of Civil Engineering at Nagoya Institute of
Technology, Nagoya Japan. He is a member of JSCE, JCI and JMS. His research
interests include thermal effects at concrete structures.
Satoru Shiramura is Chief Engineering at Aichi Prefectural Office, Nagoya Japan.
He is a member of JSCE.
Akihiro Sugiyama is an assistant professor of Civil Engineering at Meijo
University, Nagoya Japan. He is a member of JSCE, JCI and JMS. His research
interests include properties of concrete under high temperature curing.
Hirotomo Yoshida is a president at Nagoya Institute of Technology, Nagoya
Japan. He is a member of JSCE, JCI and JMS. His research interests include
Admixtures for concrete and high performance concrete.

INTRODUCTION

In the RCD (Roller Compacted Dam) construction method, the placing of

concrete is continuously executed over the full area layer by using heavy
machines to improve the construction speed. For this reason, the creation of
transverse joints using lateral form cannot be performed unlike the conventional
method. However, the transverse joints arc necessary to prevent cracking and
would have to be provided at intervals of about 15 m( 49 feet).

In order to create the transverse joint, this research developed a new vibration
joint cutting machine, and executed test works concerning limit time for joint
cutting, direction of joint cutting, kind of joint filling, an insertion method of joint
filling, and so on. In this paper the test methods and results are described.

STUDY OF CONSTRUCTION METHOD FOR JOINTS

Joint Creation Test (Pa•·t 1)

In order to examine the limit time for an execution interval using a joint
cutting machine, the joint cutting limit and the construction limit are studied with
the elapsed time technology after concrete placing varied.

Fig. I shows the outline of the joint cutting machine, and Table I shows the
specification. Table 2 shows the mixture proportion of concrete used for the
 Concrete Technology 447

test, and Fig. 2 shows the test places for joint cutting according to the elapsed
time.

As a compaction method being concrete is finished in two layers with each

layer 35 em thick. For each layer, compaction was performed twice without
vibration and six times with vibration. Next, in order to examine the state of
hardening of the concrete, a proctor penetration resistance test was conducted and
the variations in compressive strength with time were measured.

The proctor penetration resistance test was conducted after specimens were
subjected to wet screening using a 5 nun sieve, divided into two layers and
crammed into a mold (15cm dia. x 15cm). Each layer was compacted for 20
seconds by a vibrator. The specimens intended for a strength test were prepared
by using concrete subjected to wet screening with a 40 mm sieve divided into
three layers, placed into a mold( 15cm dia. x 30cm). Each layer was compected
by vibratOr for 30 seconds.

Table 3 shows the test result using the above described method. From this
result, it is presumed that the time which allows joint cutting is within about four
hours after mixing of the concrete was completed.

Fig. 3 shows the relationship between the proctor penetration resistance value
and time. It indicates that the penetration resistance value which allows joint
cutting is 13.73 MPa or less. Fig. 4 shows the relationship between
compressive strength and joint cutting time. It indicates that the compressive
strength which allows joint cutting is O.OS MPa.

Joint Fol'mation Test (Pal't 2)

A joint formation test was further conducted using as variable parameters :
mixture proportion, layer thickness, compaction method, etc. This was done
after the concrete was compacted twice without vibration and twelve times with
vibration for the mixture proportion shown in Table 4 and a layer thickness of 70
em every one hour for four hours after concrete placing.

The test result are given in Table 5. It on therefore be concluded that up to

four hours can be allowed for joint cutting. Thcr after, it is impossible to cut a
joint. Table 6 shows the test result obtained by inserting joint material into an
opcning(sharp edge dimensions : 16mm thick, 70 em high, 200 em long) after
joint cutting.
448 lisaka

DlSCUSSION

From the above described tests on joint cutting the following parameters arc
discussed.

Limit Time fot· .Joint Fol'mation

The limit time for joint formation is about four hours after termination of
concrete mixing. In consideration of ambient temperature, however, a joint is
preferably formed within two to three hours after the end of concrete mixing.
Additionally, the limit time for joint creation becomes longer in cold weather due
to the lower ambient temperatures and their effect on time of set.

Dit·ection of Joint Cuttin1:

Based on the experience of several operators and viewers, the joint cutting
blade should preferably be set in the operating direction for execution. When
set in a direction perpendicular to the operating direction for execution, it
becomes uncertain to distinguish the perpendicular from the tangential direction
to the blade plate there by worsening the construction properties of the joints.

I njcction of Joint Fill in~:

It was decided to insert joint filling manually after joint cutting, and a test
was conducted by using a method shown in Table 6. Best results arc obtained
when inserting plywood. According to for the tests the joint filling has to be
inserted at the time the joint cutting is made. It is better to usc a galvanized
iron sheet
(t = 0.25mm) as joint filling, make its tip end in a hook, allow the hook to touch a
joint cutting blade, and then insert the plywood the moment joint cutting is
performed.

In the case of a single sheet of galvanized iron, the tip hook portion of the
galvanized iron sheet was cut after a lapse of one hour and could not be inserted.
On the other hand, when it was made twofold for execution, it could be inserted at
a predetermined height even after a lapse of two hours (Photo. I).

New Method of Joint Fol'mation

At the beginning, a joint was created after the concrete compacted using a
vibration roller. The formation of joint after compaction caused the following
the concrete problems:
a. Loosen compacted concrete.
b. Transverse movement of already compacted coarse aggregate.
c. Longer time to perform the operation, thus delaying the execution process.
d. The tamper rcvibrating plate effect on the surroundings.
c. Roughened compacted surface accompanied by movement after joint cutting.
f. Trouble easily occurs in the operation of the machines after compaction.
Hence, because of these problems further studies were conducted. It was
 Concrete Technology 449

found that the following method to form joints after concrete is leveled would be
to insert joint filler before compaction by a vibration roller. This is because the
concrete was soft before compaction, and the joint formation time became shorter
making the operation easier.

By hooking a galvanized iron sheet twofold after leveling the concrete, the
sheet embrace the joint cutting blade. There by easily create a joint without
disturbing the concrete. In this manner the construction speed was also
increased.

CONCLUSIONS

The RCD construction method increases the construction speed by executing

the works over the full area layer, when it is necessary to create transverse joint.
In order to create such a joint, a joint cutting machine was developed which limits
the time for joint formation.

It was found that the limit time for joint formation is about four hours after
completion of the concrete mixture. Also, the joint cutting blade should be
preferably set in the operating direction. It was found better where the tip end of
a galvanized iron sheet as joint filling is bent twofold. It is allowed the sheet to
embrace a joint cutting blade when inserted at the start of the joint cutting
operation.

If joint is created before compaction using a vibration roller, it is not

necessary to loosen the concrete already compacted, but the time to perform the
operation becomes shorter, and it is easier to execute the work. The same is
applicable to the execution of work for the intermediate height to the upper
portion of the body of dam. After the transverse joint was created by using such
a method, it became apparent that the construction method is easy, the
construction speed is fast, and economical. Consequently this method has been
adopted for many dams.

REFERENCE

I) S.Shiramura and N.Suzuki " CHARACTERISTICS OF THE RCD

CONSTRUCTION METHOD AND THE RCC CONSTRUCTION METHOD"
JSCE, (Japanese), No. 484, V-22, pp.77-86, 1994.
2) N.Suzuki, T.lisaka', 1-I.Umchara, S.Shiramura, W.Wu "COMPACTION
CHARACTERISTICS OF ROLLER COMPACTED DAM CONCRETE"
International Symposium on NEW DEVELOPMENT IN CONCRETE SCIENCE
AND TECHNOLOGY (De CSAT 95), pp.867-872, Nanjing China, 1995.
450 lisaka

TABLE 1-THE SPECIFICATION OF JOINT CUTTING MACHINE

Form of machine 12-HVC-64 vibiBting m&l:hine(joint cutting)

Form of eosine Crora type wheel drive diesel engine

Weight of machine II.S ton

Size of joint cutting 16 mm thick • 900 mm high • 2.000 mm long

Number of vibmtion 0-1,850 IJlll1

Amplitude of vibration 6.S mm

Reclaimpower of blade

Style of joint cutting

. 3 ton

Revolving and side drain type for blade boom

TABLE 2-MIXTURE PROPORTION OF CONCRETE

Unit weight (kg/m 1 )

Oux W/(C+F) F/(C+F) S/a air w C+F s G Admixture

(rn) (%) (%) (%) (%) agent

70 83.3 30 34 2.5±0.5 100 120 745 1502 0.3

TABLE 3-THE RESULT OF JOINT CUTTING FOR LIMIT TIME

Joint culling Finished I.imittimc Lapse time
time for for joint
places placing cutting (minute)

9: 53 14: 25 272

10: 39 IS: IS 274

10: 51 IS: 45 294

10: 51 14: 45 234

TABLE 4-MIXTURE PROPORTION OF CONCRETE

Unit weighl(kglm ')
Gmax S/a W/(CIF) F/(C+I') c F w s G Admixture
(mm) (%) (%) (%) agent
80 34 91.7 30 84 36 110 752 1476 0.3
 TABLE 5-THE CONDITION OF JOINT CUTTING FOR LAPSE TIME
After one hour (lapse time) After two hours (lapse time) After three hours(lapse time) After four hours(lapse time)
Penetration
!29 1Pa(188 psi) 4. 44 1Pa(690 psi) 6. 04 1Pa(880 psi) !3. 73 1Pa(2. 000 psi)
value
Time of
.. -- .. - 192 sec 192 sec 296 sec
joint cutting

The joint cutting was performed three times The joint opening thickness was The portion of the joint
Condition (2m in length x 3times=6m), but twice among about I em, with few filling-up,etc., was disturbed.
of these three times, the joint filling(plywood) and was substantilly completely The portion around the
I
joint could not be inserted because of filling-up. created. same to left joint was disturbed.
I
cutting The remaining one time was also to such a The joint was some what disturbed,
degree that two sheets, among five sheets, but this was the limit for which the
a number of sheets of joint material required, joint cutting was allowed.
can be inserted.
C")
=
=
-
...
Condition It was in a state in which concrete has The crack was partly seen, but it was Until lapsed time of two hours, a guide The portion around the n
of surface protruded within a range of 30om around the a smaller amount as compared with angle was used during execution of works, joint was disturbed. CD
of concrete joint, causing crack. CD
lapsed time of one hour. but after a lapse of three hours, the guide
-1
angle was removed for joint cutting. In this CD
n
case, the protuberance or crack was reduced. :::r
=
=
=
~-

=
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-'="
c.n
452 lisaka

TABLE 6-THE KIND OF JOINT FILLING AND INSERTION TEST RESULT

Kind of Joint Filling Injection Test Result

Manually inserted. This is fragile, and the

Waxed corrugated board force cannot be applied there to during
inserting.

Manually inserted. It has dequate stiffness, and

Plywood good construction properties.
It is easy to remove the projection from the
concrete surfaceafter insertion.

Being a thin iron sheet, it has no stiffness

but it is easily defonned during transportation
Galvm1ized iron sheet and insertion.
It is possible to insert by means of a machine,
and easiest toexecute the works.

Manually inserted. Unit price is expensive.

Vinyl chloride sheet It is difficult to remove the projection after
insertion.
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Fig. 2-The specification of joint cutting test places
 Concrete Technology 455

Fig. 3-Proctor penetration resistance value versus joint cutting time

20.58

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mean em era ure 16.1
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0 47 77 107137167197227257287
Age (minute)

Fig. 4-The relation between compressive strength and joint cutting time

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456 lisaka

Fig. 5-Photograph of the creation of joint