Presented to: Louisiana Transportation Conference February 26, 2018 Presenter: Corey Zollinger, P.E. - 1 -
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 -
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 -
MULTIPLE PERSONALITIES Concrete rigid pavement Portland Cement Roller-Compacted Concrete Asphalt paver compaction Soils Proctor test density test Moisture Content - 4 -
1975 1977 1979 1981 1983 1985 1987 1989 1991 1993 1995 1997 1999 2001 2003 2005 2007 2009 2011 2013 2015 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 2.5 2.0 1.5 1.0 0.5 Yearly SY Cumulative SY 25 20 15 10 5 Cumulative RCC SY 0.0-1975 1999 2000-2010 2011-2013 2014-2016 # of Projects 71 101 197 226 SY 2,999,771 8,933,250 4,993,296 4,955,036-5 -
Pavement Area (SY) RCC IS BEING USED IN NEARLY ALL PAVEMENT APPLICATIONS RCC Paving Area by Market Segment 1200000 1000000 800000 2011 600000 2012 2013 2014 400000 2015 2016 200000 0 Intermodal Industrial Commercial Port Roadway Market Segment - 6 -
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 385 - Greenville, SC I 75 Tift Cook, GA - 7 -
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 -
I-285 SHOULDER REPLACEMENT (13 yrs old, no distress) Atlanta, GA - 9 -
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 - 10 -
LAMESA DRIVE MIDLAND, TX - 2014-11 -
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 - 12 -
# of Projects PRIVATE INDUSTRY CONTINUES TO LEAD IN RCC PAVEMENT USE Owner Type by Project 70 60 50 40 30 20 10 2011 2012 2013 2014 2015 2016 - Private Public Owner Type - 13 -
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Completing 3 different Projects: North Carolina, Alabama, Arkansas Pavement area: 3.5 million sq. ft. of 10 RCC - 15 -
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 - 16 -
# of Projects # of Projects PAVEMENT THICKNESSES ARE TYPICAL FOR CONCRETE PAVING Projects Tend to Range From 1,000 to 100,00 SY 50 45 40 35 30 25 20 15 10 5 0 Pavement Thickness by Project 4" - 5.5" 6" - 7" 7.5" - 10" >10" Pavement Thickness 2011 2012 2013 2014 2015 2016 60 50 40 30 20 10 0 Project Size by Project 0-1,000 SY 1,001-10,000 SY 10,001-100,000 SY >100,000 SY Surface Area 2014 2015 2016-17 -
RCC PAVEMENT COUNCIL IS THE INDUSTRY ORGANIZATION FOCUSED ON PROVIDING RESOURCES FOR RCC WWW.RCCPAVEMENTCOUNCIL.ORG - 18 -
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 - 19 -
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 - 14.5 Acres RCC Thickness - 7 8 inches Initial Construction - 1987. Location - Denver, CO Pavement Area - 28 RCC Thickness - 15 20 inches Initial Construction - 1986-20 -
RCC EXPLORER DATABASE SHOWS WHERE RCC HAS BEEN DONE rcc.acpa.org - 21 -
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
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
The Research Yuma, Arizona
The Research Wichita, KS
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
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 - 27 -
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 - 28 -
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 1,000,000 500,000 - Natural DG Asphalt Surface Type 2011 2012 2013 2014 2015 2016-29 -
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 - 30 -
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 1,000,000 2011 2012 2013 2014 2015 500,000 2016 - Natural DG Asphalt Trowelled RCC Surface Type - 31 -
% 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) 50 40 47 36 46 Compressive Strength 3,000-5,000 4,000-10,000 30 30 Flexural Strength (MOR) 500 700 500-1,000 20 10 0 15 12 7 3 Cement + FA Coarse Agg Fine Agg Water Elastic Modulus 3.0 5.0 million Conventional Concrete RCC 3.0 5.5 million Conventional Concrete Roller Compacted Concrete - 32 -
Percent Passing (%) MIXTURE DESIGN EXAMPLE RCC Aggregate 45 Power Gradation Max Density Gradation Plot 100.0 90.0 80.0 70.0 60.0 RCC Spec Upper Limit Spec Lower Limit 1/2 in Power 45 3/4 in Power 45 1 in Power 45 50.0 40.0 30.0 20.0 10.0 0.0 #200 #100 #16 # 4 3/8" 1/2" 3/4" 1" Sieve Size - 33 -
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 - 34 -
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) 35-35 -
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 36-36 -
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 - 37 -
Pavement Area (SY) RCC IS MOST COMMONLY PRODUCED WITH PUGMILLS Mixer Type by Area 1,600,000 1,400,000 1,200,000 1,000,000 800,000 600,000 400,000 2014 2015 2016 200,000 0 Central Tilt Drum Central Twin Shaft Dry Batch Pugmill Spiral Shaft Mixing Plant Type - 38 -
CONTINUOUS RCC MIXING PLANT (PUGMILL) IN ACTION - 39 -
RCC IS PLACED WITH ASPHALT PAVERS Achieving Density & Smoothness is Critical - 40 -
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. - 41 -
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 1,000,000 2011 2012 2013 2014 2015 500,000 2016 - High Density Medium Density Standard Surface Type - 42 -
ROLLERS ARE USED TO ACHIEVE DENSITY AND PROVIDE FINISH Initial Compaction Initial: 10-12 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 - 43 -
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 - 44 -
IN-PLACE WET MAT & JOINT DENSITY TESTING TEST STANDARD PRECISION MIN. FREQUENCY ACCEPTANCE ASTM C1040 1.4 pcf (d2s) 300 750 CY Ave. of 4 98% RC 0 < 96% RC - 45 -
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 - 46 -
FABRICATING COMPRESSION TEST CYLINDERS EQUIPMENT - 47 -
WITH THE RIGHT EQUIPMENT, RIGHT KNOW HOW, AND PROPER INSPECTION A SUCCESSFUL PROJECT IS POSSIBLE Quary Road, Victorville, CA - 48 -
WITH THE RIGHT EQUIPMENT, RIGHT KNOW HOW, AND PROPER INSPECTION A SUCCESSFUL PROJECT IS POSSIBLE Quarry Road, Victorville, CA - 49 -
Questions? Corey J. Zollinger, P.E. coreyj.zollinger@cemex.com 713-722-6084-50 -