Use of Roller Compacted Concrete By GDOT. Presented By: Joe W. Sheffield, PE Georgia Department of Transportation District Engineer, Tifton, GA

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1 Use of Roller Compacted Concrete By GDOT Presented By: Joe W. Sheffield, PE Georgia Department of Transportation District Engineer, Tifton, GA

2 First Use of RCC By Georgia DOT I-285 Atlanta, GA 2005 Traffic: 140,000 to 170,000 AADT Truck Traffic: 20%

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4 Design Loading Analysis Table 1 RCC Thickness Required Allowable Interior Load Repetitions Over Lifetime of RCC Pavement Design Life in Years 20 yr 10 yr Allowable Daily Repetitions 5 yr

5 Existing Asphalt Shoulder Removed

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12 Design and Acceptance RCC: Required 28-day Mix Design Strength of 4,000 psi Cement: 500 lbs/cy Acceptance based on density- 98% AASHTO T-180 or 28-day core strength of 3500 psi Core strength : 3980 psi avg Cylinder strength : 3964 psi avg

13 Concrete Plant

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16 Completed Shoulder

17 Rumble Strips

18 Finished Product

19 March 2010

20 RECONSTRUCTION OF SR 6 RCC SHOULDER RCC MEDIAN

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24 RCC 500 lbs/cy cement 5500 psi compressive strength

25 I-985 Gainesville, GA 6000 Cubic Yards of 7 RCC Pavement. 10 Inside Shoulders used for temporary lane. 2.5 Asphalt Overlay for Rideability.

26 I-985 Gainesville, GA

27 I-985 Gainesville, GA

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29 After Removal of Asphalt Layer 2009

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31 I-85 Kia Interchange LaGrange, GA 6600 Cubic Yards of 12 RCC Pavement. 10 Outside Shoulders. First use of Dual Lift RCC Shoulders in US.

32 I-85 Kia Interchange LaGrange, GA

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35 GDOT MAINTENANCE FACILITY

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38 Current Project I-75 Widening and Reconstruction in Cook and Tift Counties

39 NH-75-1(206) Cook CSNHS (073) Tift Reconstruct 10 miles of I-75 in northern Cook and southern Tift Counties Let to Contract Successful low bidder was Archer Western Contractors Ltd. Bid Amount: $ 128,485, Contract completion date of

40 NH-75-1(206) Cook CSNHS (073) Tift

41 NH-75-1(206) Cook CSNHS (073) Tift Project in a nutshell Remove existing 4 lanes plain PCC pavement Install 12 Graded Aggregate Base Place mm asphalt superpave Install 6 lanes of 12 Continuous Reinforced Concrete Pavement (413,661 SY) Install Concrete median barrier (51,785 LF) Install inside and outside paved shoulders

42 NH-75-1(206) Cook CSNHS (073) Tift Stage construction was required 51,000 vpd 24% trucks Contractor chose to use Roller Compacted Concrete alternate on outside shoulder Staging called for SB outside shoulder to carry mainline traffic

43 NH-75-1(206) Cook CSNHS (073) Tift

44 NH-75-1(206) Cook CSNHS (073) Tift RCC Shoulder SBL Subcontractor: Site Prep Inc. of North Carolina RCC Paving SBL began: and RCC Paving SBL concluded: and Plant was located on the project SBL Shoulder opened to Stage Construction traffic on: and

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51 NH-75-1(206) Cook CSNHS (073) Tift

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53 NH-75-1(206) Cook CSNHS (073) Tift Shortly after opening to traffic RCC began to show problems on the surface Surface looked like asphalt stripping Surface has continued to ravel and spall Contractor has repaired areas with epoxy based patches

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62 GDOT Specification Density Requirements: In-place field density will be not less than 98% of the average maximum laboratory density obtained according to AASHTO T 180, Method D, based on a moving average of five consecutive tests, with no test below 95%. RCC properly placed and compacted, but not meeting these requirements will be cored and tested at no additional cost.

63 GDOT Specification RCC pavement not meeting density requirements outlined in Subsection D.8, Density Requirements will be accepted based on compressive strength development at 28 days. The compressive strength value shall be at least 3,500 psi (25 MPa).

64 GDOT Specification No Direct Requirement for a test section Rolling: Determine the sequence and number of passes by vibratory and non-vibratory rollers to obtain the specified density and surface finish. Only operate rollers in the vibratory mode while in motion. Rubber-tire rollers may be used for final compaction.

65 GDOT Specification No Direct Requirement for a test section Paver Requirements: Adjust the paver and regulate the speed to prevent segregation and provide a surface course that is smooth and continuous without tears and pulling.

66 GDOT SPECIFICATION Place RCC with an asphalt paver meeting the following requirements: 1. Equip the paver with compacting devices capable of producing a RCC pavement with a minimum of 90% of the maximum density in accordance with AASHTO T 180, Method D. 2. Spread and finish the RCC material without segregation, to the required thickness, smoothness, surface texture, cross-section and grade using a paver of suitable weight and stability.

67 GDOT SPECIFICATION Immediately begin compaction behind the placement of RCC material and complete within 60 minutes of the start of mixing at the plant. This time may be increased or decreased depending on the use of set retarding admixtures or ambient weather conditions of temperature, wind and humidity.

68 GDOT SPECIFICATION Multiple Lift Placement: For multi-layer construction, a horizontal joint is considered a fresh joint when an subsequent RCC lift is placed within 60 minutes of placing the previous lift, with time adjusted depending on use of retarders or ambient weather conditions.

69 GDOT SPECIFICATIONS If segregation occurs in the RCC during paving operations, CEASE the spreading until the cause is determined and corrected to the satisfaction of the Engineer. If the Engineer determines the segregation to be severe, remove and replace the segregated area at no additional cost.

70 Upcoming Project I-16 Replacement of Outside Lane 9 inch RCC for Inside and outside shoulders 330,000 sy Bid Price $18.39 sy

71 QUESTIONS OR COMMENTS