Presented to: Louisiana Transportation Conference February 26, Presenter: Corey Zollinger, P.E

Size: px

Start display at page:

Download "Presented to: Louisiana Transportation Conference February 26, Presenter: Corey Zollinger, P.E"

Horatio Ellis
5 years ago
Views:

1 Presented to: Louisiana Transportation Conference February 26, 2018 Presenter: Corey Zollinger, P.E

2 AGENDA What is Roller Compacted Concrete, Where has it Been Used, and Why? RCC Construction Process Surface Appearance Mix Design Mix Production Paving Operation Quality Control Curing & Saw Cutting - 2 -

No reinforcing steel or dowels. No finishing. Compacted with rollers.

3 ROLLER COMPACTED CONCRETE IS A ZERO SLUMP CONCRETE A negative-slump concrete that is compacted not consolidated. Placed with High Density Asphalt Machine No forms. No reinforcing steel or dowels. No finishing. Compacted with rollers. No internal vibration. (consistency of damp gravel). RCC is a concrete pavement that is placed in a different way! - 3 -

4 MULTIPLE PERSONALITIES Concrete rigid pavement Portland Cement Roller-Compacted Concrete Asphalt paver compaction Soils Proctor test density test Moisture Content - 4 -

5 Millions USE OF RCC PAVEMENTS IN US RCC utilization began growing in early 2000 s & is now growing at a faster rate RCC SY PAVED BY YEAR Yearly RCC SY Millions Yearly SY Cumulative SY Cumulative RCC SY # of Projects SY 2,999,771 8,933,250 4,993,296 4,955,

6 Pavement Area (SY) RCC IS BEING USED IN NEARLY ALL PAVEMENT APPLICATIONS RCC Paving Area by Market Segment Intermodal Industrial Commercial Port Roadway Market Segment - 6 -

7 OVER THE PAST 13 YEARS, DOT S HAVE PAVED SHOULDERS & SURFACE ROADS USING RCC I 85 Greensboro, NC I-85 Interchange Lagrange, GA Crossgate Road Port Wentworth, GA US 78 Aiken, SC I Greenville, SC I 75 Tift Cook, GA - 7 -

8 I-285 SHOULDER REPLACEMENT Atlanta, GA (2005) 35 Lane Miles of 10 Shoulder 38,500 CY of material placed Material placed on weekends only - 8 -

9 I-285 SHOULDER REPLACEMENT (13 yrs old, no distress) Atlanta, GA - 9 -

use of RCC in travel way in United States Project won 2007 SCAN Quality Award for concrete pavement

10 STATE ROUTE 6 Powder Springs, GA Pavement Design Information Owner: Georgia DOT Use Type: State Route shoulder and Median Year Built: 2006 Thickness: 7 RCC (Shoulder & Median) Quantity: 16,500 CY Additional Details First use of RCC in travel way in United States Project won 2007 SCAN Quality Award for concrete pavement construction ADT - 17,000, 5% trucks 22 M ESALS RCC used for travel lane during construction 12 years old No cracking

11 LAMESA DRIVE MIDLAND, TX

12 COLONY RIDGE DEVELOPMENT RCC paving solution for Subdivision Development. Five- inch-thick pavement More than 1.1 million square feet of roadways. 70 miles of neighborhood streets. 22-foot-wide streets can last up to 20 years without failures

13 # of Projects PRIVATE INDUSTRY CONTINUES TO LEAD IN RCC PAVEMENT USE Owner Type by Project Private Public Owner Type

14 - 14 -

15 Completing 3 different Projects: North Carolina, Alabama, Arkansas Pavement area: 3.5 million sq. ft. of 10 RCC

16 Lowe s Distribution Center 7 RCC was selected in lieu of asphalt by the owner based on pricing and performance expectations. The RCC was placed in 30-foot pavement lanes with control joints cut longitudinally and transversely at 15 feet. Project Description Distribution Facility Project Size Over 3 Million SF Project Duration 2.5 Months

17 # of Projects # of Projects PAVEMENT THICKNESSES ARE TYPICAL FOR CONCRETE PAVING Projects Tend to Range From 1,000 to 100,00 SY Pavement Thickness by Project 4" - 5.5" 6" - 7" 7.5" - 10" >10" Pavement Thickness Project Size by Project 0-1,000 SY 1,001-10,000 SY 10, ,000 SY >100,000 SY Surface Area

18 RCC PAVEMENT COUNCIL IS THE INDUSTRY ORGANIZATION FOCUSED ON PROVIDING RESOURCES FOR RCC

Covers all aspects Available through PCA Guideline

19 THERE ARE EXCELLENT TECHNICAL REFERENCES AVAILABLE Developed by the CPTech Center at Iowa State Covers all aspects Available through PCA Guideline specification for Exposed Surface RCC pavements

RCC PAVEMENT COUNCIL PROVIDES CASE STUDIES ON

5 Acres RCC Thickness - 7 8 inches Initial

20 RCC PAVEMENT COUNCIL PROVIDES CASE STUDIES ON LONG LIFE RCC PAVEMENTS Starting in 2004, the Georgia DOT (GDOT) 17.3 mile stretch of I 285 between I 85 To date, no maintenance has been done. Location - Austin, Texas Pavement Area Acres RCC Thickness inches Initial Construction Location - Denver, CO Pavement Area - 28 RCC Thickness inches Initial Construction

21 RCC EXPLORER DATABASE SHOWS WHERE RCC HAS BEEN DONE rcc.acpa.org

22 City of Roseville, CA Challenge Maintenance Funding Roseville 1,000 lane miles of asphalt roadway Need to maintain 100 lane miles/year $8.5 million City averages $4.4 million/year available for roadway maintenance - about half of what is needed

23 The Research RCC/AC Engineering Cost Estimates for Pleasant Grove Option Construct 50-yr. Maint. Lifecycle Cost RCC over cementtreated subgrade Asphalt over cement-treated subgrade $914,186 $490,000 $1,404,186 $1,254,962 $785,840 $2,040,802

24 The Research Yuma, Arizona

25 The Research Wichita, KS

26 Pilot Project Complete reconstruction of three sections of failed road Washington, Atkinson/Denio, Hickory Three differing road types arterial, collector, residential Three different finishes natural, diamond grind, troweled

27 AGENDA What is Roller Compacted Concrete, Where has it Been Used, and Why? RCC Construction Process Surface Type Mix Design Mix Production Paving Operation Quality Control Curing & Saw Cutting

28 Factors Applications THE FINAL SURFACE TYPE DICTATES THE NECESSARY TECHNIQUES & EQUIPMENT NEEDED TO BE SUCCESSFUL Natural RCC Diamond Ground RCC Asphalt Ports Distribution centers Industrial yards Residential roads Parking lots Collector / Arterial local roads Highway Shoulders State routes Any pavement type Lowest Cost Most sensitive to contractor skill level Least smooth Ugly surface appearance Medium cost increase Increased construction time Improved smoothness, skid resistance Reduced noise Highest cost Increased construction time Least sensitive to contractor skill level Improved smoothness, skid resistance

Pavement Area (SY) THE FINAL SURFACE TYPE

2,500,000 2,000,000 1,500,000 1,000,000 500,000

29 Pavement Area (SY) THE FINAL SURFACE TYPE DICTATES THE NECESSARY TECHNIQUES & EQUIPMENT NEEDED TO BE SUCCESSFUL Natural RCC Diamond Ground RCC Asphalt Surface Type by Area 2,500,000 2,000,000 1,500,000 1,000, ,000 - Natural DG Asphalt Surface Type

30 THE SURFACE APPEARANCE AND TEXTURE OF RCC IS SIMILAR TO ASPHALT PAVEMENT Similar appearance & texture as asphalt only light grey instead of black Surface texture depends on aggregate gradation and paste content Diamond ground RCC is similar to diamond ground concrete Diamond Ground Conventional Concrete PCC RCC Diamond Ground RCC HMA

31 Pavement Area (SY) NATURAL RCC CONTINUES TO HAVE THE MOST MARKET SHARE WITH TROWELLIN GROWING IN POPULARITY Surface Type by Area 2,500,000 2,000,000 1,500,000 1,000, , Natural DG Asphalt Trowelled RCC Surface Type

32 % Total Weight RCC MIX DESIGN USES SAME MATERIALS AS CONVENTIONAL CONCRETE, HOWEVER IN DIFFERENT COMBINATIONS Achieves Similar or Better Engineering Properties Than Conventional Concrete 60 Typical Mix Design Typical Engineering Properties Conventional (psi) RCC (psi) Compressive Strength 3,000-5,000 4,000-10, Flexural Strength (MOR) , Cement + FA Coarse Agg Fine Agg Water Elastic Modulus million Conventional Concrete RCC million Conventional Concrete Roller Compacted Concrete

33 Percent Passing (%) MIXTURE DESIGN EXAMPLE RCC Aggregate 45 Power Gradation Max Density Gradation Plot RCC Spec Upper Limit Spec Lower Limit 1/2 in Power 45 3/4 in Power 45 1 in Power #200 #100 #16 # 4 3/8" 1/2" 3/4" 1" Sieve Size

Aggregate Properties Performance Characteristics WHAT

Roller Marks Compaction Segregation Moisture Content

34 Aggregate Properties Performance Characteristics WHAT AGGREGATE & MIX PROPERTIES IMPACT PERFORMANCE CHARACTERISTICS? Screed Stability Workability Surface Appearance Strength Roller Marks Compaction Segregation Moisture Content Durability Fatigue Cold Joint Stability Aggregate Shape Top Size Size Distribution Mineralogy Absorption Sand Type

add water Step 3: Develop moisture density relationship plots Perform a modified Proctor test at the selected cement content Construct

35 Optimum Moisture MIXTURE DESIGN PROCEDURE Step 2: Select a mid range cementitious content Minimum 450 lbs cement / CY 12-14% Type I Portland cement is selected for the first trial batch Based % on weight, so make enough and do not worry about volumes yet Mix the cement dry, and then add water Step 3: Develop moisture density relationship plots Perform a modified Proctor test at the selected cement content Construct moisture-density relationship curve (Use spreadsheet) Determine Maximum Dry Density (MDD) and Optimum Moisture Content (OMC) Maximum Dry Density (ASTM D1557)

determined in step 3 Use varying cementitious contents such as 10, 12 and 14 percent

36 Step 4: Cast samples to measure compressive strength (ASTM C 1435) Calculate trial mix proportions Batch RCC materials Maintain percent Optimum Moisture Content as determined in step 3 Use varying cementitious contents such as 10, 12 and 14 percent Make compressive strength test cylinders for each cement content MIXTURE DESIGN PROCEDURE

Factors to Consider High production rates: 50 to

materials Highly consistent mix properties, Mobile 1

location, obtain permits Self contained Gen set,

A PUGMILL MIXER DUE TO HIGH PRODUCTION RATES &

37 Factors to Consider High production rates: 50 to 300+CY / hr Excellent mixing efficiency for dry materials Highly consistent mix properties, Mobile 1 load, 1 Day Set up and calibration Need to find good location, obtain permits Self contained Gen set, batch house 2 to 3 man operation WE RECOMMEND USING A PUGMILL MIXER DUE TO HIGH PRODUCTION RATES & EFFICIENT MIXING PROCESS # of Aggregates depends on Feeder system

38 Pavement Area (SY) RCC IS MOST COMMONLY PRODUCED WITH PUGMILLS Mixer Type by Area 1,600,000 1,400,000 1,200,000 1,000, , , , ,000 0 Central Tilt Drum Central Twin Shaft Dry Batch Pugmill Spiral Shaft Mixing Plant Type

39 CONTINUOUS RCC MIXING PLANT (PUGMILL) IN ACTION

40 RCC IS PLACED WITH ASPHALT PAVERS Achieving Density & Smoothness is Critical

41 SPECIFICATION: PAVING MACHINE (2) Paver. RCC shall be placed with a high-density asphalt type paver equipped with 2 or more compacting devices including tamping bars or pressure bars subject to approval by the City. The paver shall be capable of placing RCC to a minimum of 90% of the maximum wet density in accordance with ASTM D 1557 or equivalent test method. The paver shall be of suitable weight and stability to spread and finish the RCC material, without segregation, to the required thickness, smoothness, surface texture, cross-section and grade

42 Pavement Area (SY) RCC IS MOST COMMONLY PLACED WITH HIGH DENSITY PAVERS Screed Type by Area 2,500,000 2,000,000 1,500,000 1,000, , High Density Medium Density Standard Surface Type

ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH Initial Compaction Initial: 10-12 ton

) Adjust roll pattern based on moisture content Compact to 98% density - wet Adjust moisture

Rolling Combination, dual steel or rubber tired Maximum weight - 6 short ton Remove roller marks

43 ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH Initial Compaction Initial: ton static & vibratory roller Establish roll pattern (check density a lot!) Adjust roll pattern based on moisture content Compact to 98% density - wet Adjust moisture content if needed impacts smoothness & compaction Finer mixes achieve density easier Finish Rolling Combination, dual steel or rubber tired Maximum weight - 6 short ton Remove roller marks Once completed, keep roller off of the area Fairforest Way Greenville, SC Grape Creek Road San Angelo, TX Fairforest Way Greenville, SC

1600 Ensures durable surface Saw Cut & Fill Joints More aesthetically pleasing Early entry saw very effective, shortly

44 WHEN CURED & SAW CUT RCC PERFORMANCE IMPROVES Curing Applied at same rate or slightly higher than conventional concrete Ensure uniformity with application process Apply as soon as possible behind roller operation Recommend WR Meadows 1200 to 1600 Ensures durable surface Saw Cut & Fill Joints More aesthetically pleasing Early entry saw very effective, shortly following placement Recommend sawing within 2-6 hours to avoid uncontrolled cracking Depth: 1 to 2 Spacing: Maximum 36 times thickness

45 IN-PLACE WET MAT & JOINT DENSITY TESTING TEST STANDARD PRECISION MIN. FREQUENCY ACCEPTANCE ASTM C pcf (d2s) CY Ave. of 4 98% RC 0 < 96% RC

46 RCC MIXTURE MOISTURE CONTENT TESTING TEST STANDARD ASTM C566 PRECISION 0.79% (d2s for aggregate) MIN. FREQUENCY Often / As needed ACCEPTANCE ± 1-2% of Optimum

47 FABRICATING COMPRESSION TEST CYLINDERS EQUIPMENT

48 WITH THE RIGHT EQUIPMENT, RIGHT KNOW HOW, AND PROPER INSPECTION A SUCCESSFUL PROJECT IS POSSIBLE Quary Road, Victorville, CA

49 WITH THE RIGHT EQUIPMENT, RIGHT KNOW HOW, AND PROPER INSPECTION A SUCCESSFUL PROJECT IS POSSIBLE Quarry Road, Victorville, CA

50 Questions? Corey J. Zollinger, P.E

Emerging Concrete Pavement Solutions Roller Compacted Concrete (RCC)

Emerging Concrete Pavement Solutions Roller Compacted Concrete (RCC) Presented to: APWA Nor Cal November 3 rd, 2016 Presenters: Jason Shykowsi, P.E., T.E. City of Roseville Debbie Haldeman RCC Council