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ROLLER CO M PACTED CO NCRETE ROLLER CO M PACTED CO NCRETE : : A A NEW M A TER IA L FO R FASTER HIG HW AY NEW M A TER IA L FO R FASTER HIG HW AY C O N STR U C TIO N C O N STR U C TIO N BY BY J J . . B B . . Sengupta Sengupta R igid Pavem ents D ivision, R igid Pavem ents D ivision, C entralR oad R esearch Institute C entralR oad R esearch Institute N ew D elhi N ew D elhi

RCCP Presentation

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Page 1: RCCP Presentation

ROLLER COMPACTED CONCRETEROLLER COMPACTED CONCRETE: : A A NEW MATERIAL FOR FASTER HIGHWAY NEW MATERIAL FOR FASTER HIGHWAY

CONSTRUCTION CONSTRUCTION

BYBY

JJ..BB..SenguptaSengupta

Rigid Pavements Division,Rigid Pavements Division,

Central Road Research InstituteCentral Road Research Institute

New DelhiNew Delhi

Page 2: RCCP Presentation

INTRODUCTIONINTRODUCTIONROLLER COMPACTED CONCRETE ROLLER COMPACTED CONCRETE ((RCCRCC))

RCC as an RCC as an innovative materialinnovative material is defined as a is defined as a relatively stiff or no slump cement concrete mixture relatively stiff or no slump cement concrete mixture of aggregates, Portland cementof aggregates, Portland cement/ / Pozzolanic Pozzolanic additivesadditives//admixtures and water to be compacted by admixtures and water to be compacted by vibratoryvibratory//static rollerstatic roller..

ROLLER COMPACTED CONCRETE PAVEMENT ROLLER COMPACTED CONCRETE PAVEMENT ((RCCPRCCP))

RCCP consists of RCC laid with conventional RCCP consists of RCC laid with conventional asphaltic concrete paver, compacted with vibratory asphaltic concrete paver, compacted with vibratory road or static roller and finished with power trowel road or static roller and finished with power trowel machine or laid with slipmachine or laid with slip--form paver machineform paver machine..

Page 3: RCCP Presentation

HISTORICAL BACKGROUNDHISTORICAL BACKGROUND

RCC IN DAM CONSTRUCTIONRCC IN DAM CONSTRUCTION

The technology of RCC has evolved The technology of RCC has evolved rapidly during the past two to three rapidly during the past two to three decades and has been accepted decades and has been accepted worldwide as a fast and economical means worldwide as a fast and economical means of constructing damsof constructing dams..

A total of A total of 96 96 RCC dams have been built in RCC dams have been built in 17 17 countries showing its testimony of its countries showing its testimony of its popularity and technopopularity and techno--economic economic superiority of this technologysuperiority of this technology..

Page 4: RCCP Presentation

HISTORICAL BACKGROUND HISTORICAL BACKGROUND ((contdcontd.).)

RCC IN PAVEMENT CONSTRUCTION IN RCC IN PAVEMENT CONSTRUCTION IN THE DEVELOPED WORLDTHE DEVELOPED WORLD

RCC Pavement is an RCC Pavement is an offshoot of the traditional cement offshoot of the traditional cement treated aggregate basetreated aggregate base as used in road construction, but it as used in road construction, but it differs from conventional concrete principally in its required differs from conventional concrete principally in its required consistencyconsistency. . The use of RCC for pavement is, however, a The use of RCC for pavement is, however, a relatively recent development and the technology relatively recent development and the technology is stillis stillgrowinggrowing..

During the past decade, several During the past decade, several RCCPsRCCPs have been have been constructed in the developed world in the area of heavy duty constructed in the developed world in the area of heavy duty pavements, military vehicles roads, log sorting yards, pavements, military vehicles roads, log sorting yards, parking lots, dock yards, taxi tracks etcparking lots, dock yards, taxi tracks etc. . since since 19761976. .

In view of the rough surface of RCCP, it has not been used In view of the rough surface of RCCP, it has not been used so far in highway constructionso far in highway construction..

Page 5: RCCP Presentation

HISTORICAL BACKGROUND HISTORICAL BACKGROUND ((ContdContd.).)

RCC IN PAVEMENT CONSTRUCTION IN INDIARCC IN PAVEMENT CONSTRUCTION IN INDIA

RCC represents innovative concept, developed and RCC represents innovative concept, developed and introduced for the introduced for the first time in India by Central first time in India by Central Road Research Institute, for road constructionRoad Research Institute, for road construction..

Application of RCC has been made at several Application of RCC has been made at several

construction sites in India, since construction sites in India, since 19841984..

The application of RCC technology in pavements The application of RCC technology in pavements is in is in early stagesearly stages of development and very little of development and very little information is available in respect of its design information is available in respect of its design and construction aspectsand construction aspects

for for highway constructionhighway construction..

Page 6: RCCP Presentation

WHY RCCP ?

Based on the satisfactory performance of roller compacted concrete pavement as wearing courseand as base course, large-scale adoption of this technology is to be promoted for highway paving projects.

Capable of providing concrete with relatively equal in-situ strength and durability as compared to conventionally compacted concrete, and its engineering behaviour is also similar to that of conventional concrete.

Page 7: RCCP Presentation

MIX DESIGN

Mix design of RCC is totally different from Plain Cement Concrete (PCC) as Abraham's water/cement (W/C) ratio law does not hold in case of RCC, which is no slump concrete.

W/C ratio law holds in case of workable mixes only.

In RCC mix design, water is selected from optimum moisture content (OMC) at maximum dry density (MDD) by the soil compaction test or concrete consistency test.

The maximum size of aggregate is often 20 mmto avoid segregation of the mix.

Page 8: RCCP Presentation

MIX DESIGN (Contd.)

Mix proportions may be designed alternatively based on ACI 207 Guidelines or IRC-68.

Chemical reaction of water with cement is secondary effect. In conventional PCCpavements, W/C ratio is the only main controlling factor on which strength of concrete depends.

By replacing cement with fly ash and other mineral admixture, RCC mix can be designed

and made economical.

Page 9: RCCP Presentation

MIX DESIGN (Contd.)

To permit comparison of dry density in the field at different times, a correction factor must be applied for bound water.

CCorrection factor for bound water (Rc), owing to cement reaction, is given as :

RRcc == 00..25 25 C C x x 100100//ddcddc

Where CWhere C == cement contentcement content

== degree of cement hydration at time degree of cement hydration at time of testing of testing ((0.10.1 to to 1.01.0))

ddc = dry density of core sample (kg/m3)

Page 10: RCCP Presentation

MIX DESIGN (Contd.)

According to Anderson, degree of compaction of According to Anderson, degree of compaction of RCC is defined as RCC is defined as ::

Rd = (ddc)f x 100/(ddc)l

Where Where (ddc)f = = dry density of concrete dry density of concrete measured in the fresh state measured in the fresh state

in the field

(ddc)l = = dry density of concrete after dry density of concrete after heavy tamping heavy tamping

in the laboratory

Page 11: RCCP Presentation

PAVEM ENT DESIGN

The thickness design procedures for The thickness design procedures for RCCPRCCP are similarare similar to those for conventional to those for conventional concrete pavement, in that it is based on concrete pavement, in that it is based on keeping the keeping the flexural stresses and fatigue flexural stresses and fatigue damagedamage in pavement caused by wheel in pavement caused by wheel loads within allowable limitsloads within allowable limits. .

The design procedures developed by the The design procedures developed by the Portland Cement Association and the UPortland Cement Association and the U..SS. . Army Corps of EngineersArmy Corps of Engineers are used for are used for designing RCC pavementsdesigning RCC pavements..

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PAVEMENT DESIGN PAVEMENT DESIGN ((ContdContd.).)

The The UU..SS. . Army Corps of EngineersArmy Corps of Engineers rigid pavement rigid pavement design method is essentially, a design method is essentially, a fatigue analysisfatigue analysisbased on stresses calculated from based on stresses calculated from WestergaardWestergaard’’s s free edge load analytical methodfree edge load analytical method. . Fatigue relationFatigue relationfor concrete pavement using the for concrete pavement using the WestergaardWestergaard’’s s free edge modelfree edge model is is ::

DF DF = = 00..50 50 + + 00..25 25 log C,log C,Where, Where, DF = Design Factor

= = Concrete flexural strengthConcrete flexural strength//WestergaardWestergaard’’s calculated stresss calculated stress

C C = = Coverage of Traffic Coverage of Traffic ((Maximum NoMaximum No. . of Stress of Stress Repetitions at any point in the pavementRepetitions at any point in the pavement))

Page 13: RCCP Presentation

RCC OVERLAY DESIGN AS COMPOSITE PAVEMENT

RCC overlay on existing rigid pavement. For partially bonded overlay for composite pavements design, U.S. Army Corps of Engineer’s equation can be used for RCC overlay on existing rigid pavement :

ht = (ho1.4 - hb

1.4 )1/1.4

ht = required thickness of the top lift

ho = original monolithic thickness of the pavement

hb = thickness of the bottom lift

RCC overlay on existing flexible pavement. The existing flexible pavement can be used as a base course under RCC overlay.

Page 14: RCCP Presentation

Roller Compacted Concrete OverlayThickness = h t

Cross-section of RCC Pavement as an Overlay Over Existing Flexible Pavement

Existing Flexible PavementThickness = h b

RCC COMPOSITE PAVEMENT

Subgrade - Sub base

Page 15: RCCP Presentation

RCCP CONSTRUCTION EXPERIENCE

RCCP was constructed at several paving sites using 190mm lifts for a thickness more than 381 mm section, within an initial setting time of 30 minutes between lifts.

Dry Lean Concrete (DLC), when used as base under RCCP was jointed at longer spacing (10 m to 30 m ) and a plastic microfilm (125 micron) was used at the interface of DLC and RCCP for free sliding of pavement slab.

Sawed contraction joints were provided within 48 to 72 hours.

Page 16: RCCP Presentation

RCCP CONSTRUCTION EXPERIENCE RCCP CONSTRUCTION EXPERIENCE ((ContdContd.).)

Use of pneumatic tyre Use of pneumatic tyre vibrovibro--max rollermax roller was found to was found to be helpful to get more evenness and compactness be helpful to get more evenness and compactness of the surfaceof the surface..

Compaction of freshly placed RCC mix was Compaction of freshly placed RCC mix was carried out in an experimental stretch for a single carried out in an experimental stretch for a single lane widthlane width. .

Rolling sequence was started for RCC compaction Rolling sequence was started for RCC compaction withwith vibratoryvibratory steel wheel rollersteel wheel roller followed by followed by rubberrubber--tyredtyred rollerroller and finished finally with static steel and finished finally with static steel roller roller starting from the edgesstarting from the edges..

Page 17: RCCP Presentation

RCCP CONSTRUCTION EXPERIENCE RCCP CONSTRUCTION EXPERIENCE ((ContdContd.).)

Contraction joint spacingContraction joint spacing in RCCP was kept in RCCP was kept between between 10 10 m to m to 30 30 mm, whereas the spacing , whereas the spacing between contraction joints was at between contraction joints was at 4.54.5 m in plain m in plain cement concrete pavementcement concrete pavement. .

In the design of RCCP, In the design of RCCP, load transferload transfer at joints was at joints was taken as taken as 2525%.%.

The amount of The amount of waterwater was taken in the range of was taken in the range of 44..5 5 to to 6 6 %% by weight of total aggregates by weight of total aggregates depending upon fineness of aggregatesdepending upon fineness of aggregates..

Page 18: RCCP Presentation

RCCP CONSTRUCTION EXPERIENCE RCCP CONSTRUCTION EXPERIENCE ((ContdContd.).)

Moist curing of RCC was carried out minimum for 7 days.

Membrane curing compounds were not used as

the RCCP surface was rough and dry.

0.5% sugar by weight of cement was used as a good retarder.

The performance of RCC pavements has been observed satisfactory.

Page 19: RCCP Presentation

SUCCESSFUL CONSTRUCTION & SATISFACTORY PERFORMANCE OF ROLLER COMPACTED CONCRETE PAVEMENTS AT VARIOUS PAVING SITES IN INDIA

At District At District KarnalKarnal, village , village RamgarhRamgarh, , HaryanaHaryana as as wearing surfacewearing surface

At Village At Village RaichurRaichur,, KarnatakaKarnataka as as wearing surfacewearing surface

At At DhandharikalanDhandharikalan for container yard, for container yard, LudhianaLudhiana, , Punjab as Punjab as DLCDLC for for base coursebase course

Page 20: RCCP Presentation

SUCCESSFUL CONSTRUCTION &SATISFACTORY PERFORMANCE OF ROLLER COMPACTED CONCRETE

PAVEMENTS AT VARIOUS PAVING SITES IN INDIA (Contd.)

ADB project ADB project –– BallabhgarhBallabhgarh--MathuraMathura section as section as DLC DLC base coursebase course

MumbaiMumbai-- PunePune Expressway as Expressway as DLC base courseDLC base course

IndoreIndore--Bypass as Bypass as DLC base courseDLC base course

LehLeh--ChalunkaChalunka road, Border Roadsroad, Border Roads OrganizationOrganization, , as as

wearing coursewearing course

Page 21: RCCP Presentation

SURFACE SMOOTHNESS AND TEXTURE

Size of aggregates and type of roller play an Size of aggregates and type of roller play an important role for better surface important role for better surface smoothness and texturesmoothness and texture. . An aggregate An aggregate gradation closer to dense gradation closer to dense asphaltic asphaltic gradation is appropriategradation is appropriate. . Fines passingFines passing 75 75 micronmicron sieve should be in the range of sieve should be in the range of 55 to to 10%10%. .

To improve the To improve the rideabilityrideability for high speed for high speed traffic, RCC should be overlaid with a thin traffic, RCC should be overlaid with a thin layer of layer of fully bonded PCCfully bonded PCC or or bituminous bituminous concrete layerconcrete layer of of 44 to to 66 cm thickcm thick..

Page 22: RCCP Presentation

SURFACE SMOOTHNESS AND TEXTURE (Contd.)

Power trowel machinePower trowel machine should preferably be used should preferably be used just beforejust before the the initial setting timeinitial setting time after laying of after laying of RCC for greater evennessRCC for greater evenness ..

RCC should be laid with RCC should be laid with conventional bituminous conventional bituminous concrete paversconcrete pavers or or slip form paver machinesslip form paver machines to to achieve better riding quality achieve better riding quality for highway pavement for highway pavement constructionconstruction..

Page 23: RCCP Presentation

QUALITY CONTROL AND QUALITY QUALITY CONTROL AND QUALITY ASSURANCE ASSURANCE ((ContdContd.).)

Before compactionBefore compaction is done, the is done, the dressing dressing of the loosely spread of the loosely spread concrete surface layer must be concrete surface layer must be carried out carefully by using carried out carefully by using paver paver or straight edgeor straight edge to avoid the to avoid the occurrence of undulationoccurrence of undulation or or unevennessunevenness of the riding surfaceof the riding surface..

Page 24: RCCP Presentation

QUALITY CONTROL AND QUALITY QUALITY CONTROL AND QUALITY ASSURANCE ASSURANCE ((ContdContd.).)

The final compaction shall be carried out by The final compaction shall be carried out by rubber tyred roller or smooth tyred static rubber tyred roller or smooth tyred static rollerroller, the , the tyre marks shall be carefully tyre marks shall be carefully removedremoved from the surface by from the surface by rere--rollingrolling..

Power trowel machinePower trowel machine must be used after must be used after compaction to avoid undulation or compaction to avoid undulation or unevenness of the surface where unevenness of the surface where paver has paver has not been used not been used ..

Page 25: RCCP Presentation

QUALITY CONTROL AND QUALITY ASSURANCE (Contd,)

Initial curing shall be done by covering Initial curing shall be done by covering with wet gunny bags or polythene with wet gunny bags or polythene sheets for first twenty four hourssheets for first twenty four hours, and , and thereafter, by pond curingthereafter, by pond curing. . Liquid membrane Liquid membrane curing compound shall not be usedcuring compound shall not be used for curing for curing of RCC as the mix of RCC is already very dryof RCC as the mix of RCC is already very dry..

It is It is emphasizedemphasized that for major highway & that for major highway & expressway projects, the expressway projects, the Ready Mixed Ready Mixed Concrete Concrete ((RMCRMC)) should be used for obtaining should be used for obtaining quality rolled concretequality rolled concrete..

Page 26: RCCP Presentation

ECONOMICS OF RCC Vs PCCECONOMICS OF RCC Vs PCC

Total thickness of Total thickness of RCCRCC is generally less than is generally less than that of flexible pavement for the same loadthat of flexible pavement for the same load..

Analysis shows thatAnalysis shows that RCC isRCC is 2020% % cheapercheaperthan the plain cement concrete in material than the plain cement concrete in material cost for same loading conditionscost for same loading conditions..

Page 27: RCCP Presentation

ECONOMICS OF RCC Vs PCC ECONOMICS OF RCC Vs PCC ((ContdContd.).)

3030% % cementcement can be saved by using can be saved by using RCC as a partial replacement of RCC as a partial replacement of cement with fly ashcement with fly ash..

Economics of RCC Vs PCC as per Economics of RCC Vs PCC as per 19941994 rates as per Delhi region are as rates as per Delhi region are as followsfollows..

Page 28: RCCP Presentation

Quantity of Material per cubic meter of Quantity of Material per cubic meter of RCC vRCC v//s Conventional PCC of s Conventional PCC of

Equivalent StrengthEquivalent StrengthS.No. Item RCC PCC

Quantity (kg) Cost (Rs) Quantity(kg) Cost(Rs)

1. Cement 280 690 400 992

2. Sand 639 120 698 134

3. Fly ash 82 7 Nil Nil

4. Coarse 1198 230 1054 210

Aggregate

Total cost of materials of roller compacted concrete per cu.m = Rs 1047.00.

Total cost of materials of conventional concrete per cu.m = Rs 1336.00

Percentage saving in cost of materials alone = 20 %

Page 29: RCCP Presentation

TECHNOTECHNO--ECONOMIC BENEFITS OF ECONOMIC BENEFITS OF RCCRCC

Speedy construction.

Early removal of form work.

Equivalent strength in comparison to plain cement concrete for the same slab thickness.

The pavement can be opened to traffic after a week’s time in case of urgency.

Page 30: RCCP Presentation

TECHNOTECHNO--ECONOMIC BENEFITS OF ECONOMIC BENEFITS OF RCC RCC ((ContdContd.).)

Since the construction of Roller Compacted Concrete Pavement is similar to that of asphaltic concrete pavement, so the same machinery could be used for its construction also.

Less hydraulic shrinkage occurs due to lower cement and water contents per cu.m in the RCC mix as compared to PCC mix. This allows joints to be set further apart.

Good skid resistance and abrasion resistance.

Page 31: RCCP Presentation

TECHNOTECHNO--ECONOMIIC BENEFITS OF ECONOMIIC BENEFITS OF RCC RCC ((ContdContd.).)

Energy consumption is reduced to the tune of Energy consumption is reduced to the tune of 30 30 %% when the concrete has a high content of when the concrete has a high content of additional binders such as additional binders such as flyfly--ashash..

Overall savingOverall saving of the order of of the order of 25 25 %% has been has been achieved by using achieved by using RCCP techniqueRCCP technique versus versus conventional conventional PCC pavementPCC pavement..

Page 32: RCCP Presentation

CONCLUSIONSCONCLUSIONS

A A 1010 tonnetonne dualdual-- drum vibratory rollerdrum vibratory roller can be can be successfully used for compaction of successfully used for compaction of zerozero--slumpslump RCC pavement slabs up to RCC pavement slabs up to 250250 mm mm compactedcompacted--thickness in a single liftthickness in a single lift..

Use of Use of power trowel machinepower trowel machine for finishing the for finishing the top surface, helps to top surface, helps to improve surface textureimprove surface texture...

Page 33: RCCP Presentation

It is essential that It is essential that strict quality controlstrict quality control and and quality assurancequality assurance must be executed when must be executed when actually laying the pavementactually laying the pavement..

For For highhigh--speed trafficspeed traffic, the riding quality can , the riding quality can be still improved on highways by using be still improved on highways by using conventional bituminous concrete paverconventional bituminous concrete paver or or slipslip--form paver machineform paver machine..

RCCPRCCP is is overalloverall 2525%% economical economical as as compared to conventional compared to conventional PCC pavementPCC pavement in in construction costconstruction cost..

CONCLUSIONS CONCLUSIONS ((ContdContd.).)

Page 34: RCCP Presentation

COMPARATIVE STUDY OF THE PROPERTIES OF RCC AND PCC

SlSl..NoNo.. PROPERTYPROPERTY RCCRCC PCCPCC

11.. COMPRESSIVE STRENGTH, kgCOMPRESSIVE STRENGTH, kg//cmcm22 250250 243243

22.. FLEXURAL STRENGTH, kgFLEXURAL STRENGTH, kg//cmcm22 3232 3535

33.. MODULUS OF ELASTICITY, kgMODULUS OF ELASTICITY, kg//cmcm22 22..0 0 x x 101055 22..8 8 x x 101055

44.. SPLIT TENSILE STRENGTH, kgSPLIT TENSILE STRENGTH, kg//cmcm22 3030 2828

55.. POISSONPOISSON’’S RATIOS RATIO 0.250.25 0.220.22

66.. SHEAR STRENGTHSHEAR STRENGTH , kgkg//cmcm22 2828 1717

77.. ABRASION LOSS, ABRASION LOSS, % % 0.350.35 0.190.19

88.. SKID RESISTANCE, BPNSKID RESISTANCE, BPN 9292 9494

Page 35: RCCP Presentation

ROLLER COMPACTED CONCRETE ( RCC ) FOR ROAD CONSTRUCTION  

•RCC has made with a low water content zero slump mixture 

•RCC contains a small amount of cement compare to conventional rich structural concrete 

•The only way to compact RCC of this consistency is by roller compactor only 

•Zero-slump RCC mixture is laying and compacting by the similar machines and plants which have used in conventional dam construction and road construction 

•RCC construction method for the dams and road constructions gained popularity since 1980 due to its less expensive and fast construction method.

Page 36: RCCP Presentation

Basic Considerations for RCC Mixture Proportions will include the following performance requirements :

•Durability - depends on Strength , Cement content, aggregate quality and perfect compaction

•Strength – Required RCC strength is determined by the design of the structure in conventional concrete structures. RCC is different than conventional concrete in that the properties of the material are effected by the workability level of the mixture, the fines content and the relation of the moisture content to the optimum moisture content

•Workability – of RCC is the property that determines the RCC’s capacity to be placed and compacted successfully without harmful segregation. As RCC is zero-slump concrete mix, the workability of RCC mix cannot be measured by the conventional slump test method. The workability for RCC can be measured by modified Vebe apparatus.

•Generation of heat – in RCC depends on the cement contents in the mixture. Low water contents associated with mass RCC make possible use of very low cement contents. By adding the maximum amount of pozzolan or ground slag will minimize the Portland Cement Content. Placement temperatures is also one of the main factor to be considered to lower the Heat Generation in RCC after placing and compacting.

Page 37: RCCP Presentation

•Cementitious Materials – To determine the suitability and availability of the types of cement, pozzolan and Ground Granulated Blast-Furnace slag for the structures to be constructed. The selection of one or several suitable cementitious materials for a concrete structures depends on the exposure conditions, the type of structures, the properties of the aggregates, the availability of the cementitious material and the method of construction.

•Aggregate – The largest practical Nominal Size Aggregate should be used in mass RCC. However, RCC mixture designed with the largest aggregate size.

•Water Content - Quantity of water content may be vary on Nominal Size of the Aggregates and the type of the aggregates. From the laboratory test results show the approximate ranges of modified Vebe times corresponding to ranges of water contents and approximate mortar contents for RCC mixtures having varying Nominal Maximum Aggregate sizes.

•Admixtures - RCC mixtures do not normally have intentionally entrained air and consequently will not have a resistance to freezing and thawing in a critically saturated moisture condition. But in some Projects, air entrained agent have been used successfully.

Page 38: RCCP Presentation

The basic Quality Control Tests are almost same compare to the Quality Control Tests for the RCC Pavement construction except some additional tests has to be done for the safety

to the structure. The Quality Control Tests procedure for the RCC Dam construction is as follows:

1.Checking all materials to be used in RCC mixtures

2.Checking the Plant Calibration regularly

3.Measuring the in-place density of the compacted RCC with Nuclear Density Gauge

4.The modified Vebe Test is used frequently to determine the Consistency and Workability of the RCC mixture which will affect to the Stability and the water tightness of the of an RCC Dam structure.

5.Determining consistency for the required compaction.

6.Core sampling from the compacted RCC for measurement of Density and Strength.

7.Fabricating of RCC cylinders or cubes for the Strength Test.

Quality Control Procedure for the construction of RCC Pavement.

Page 39: RCCP Presentation

Beni Haroun RCC Dam in Algeria

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Platanovryssi RCC Dam in Greece

Page 41: RCCP Presentation

New Victoria RCC Dam in Australia

Page 42: RCCP Presentation

Upstream face view of New Victoria RCC Dam in Australia

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Downstream face view of New Victoria RCC Dam in Australia

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RCC Batching Plant and Conveyor Belt System for transporting RCC material to the RCC placing site

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RCC placing and compacting at New Victoria Dam during construction in Australia

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Placement of RCC in non spillway section

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Slip forming of upstream facing element at Platanovryssi RCC Dam in Greece during the construction

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Vibratory Roller compacting RCC directly against a downstream face of Platanovryssi RCC Dam in Greece

during the construction

Page 49: RCCP Presentation

View of Platanovryssi RCC Dam in one third of the dam height completion during construction

Page 50: RCCP Presentation

Construction Method for RCC Road Pavement - •Batching, Transporting, Placing and Compaction.

•Twin shaft Pugmill has been best achieved for RCC batching.

•RCC is dumped into the paver for paving.

•vibratory screed and tamping bar.

•Compacted with a dual drum (10 ton static weight) vibratory roller.

•Combination of Moist Curing and Membrane Curing is recommended

•The RCCP surface should be kept moist for at least 24 hours

•After 24 hours, the RCCP should be cured at least 7 days by either Water-spray Curing or covering with wet Hessian cloth  

•All vehicular traffic should be kept off the RCCP surface for at least 14 days.

Page 51: RCCP Presentation

  In general, Quality Control and Quality Assurance Program for the construction of RCC Dams and RCC Pavements are almost same. But Designer has more cautious in safety to the construction of the RCC Dams and some more control tests are conducted in the RCC Dams construction.  Basically, the following steps of Quality Control should be taken in the RCC Pavement constructions:  1.      Checking all materials to be used in RCC mixtures 2.      Checking the Plant Calibration regularly 3.      Measuring the in-place density of the compacted RCC with Nuclear Density Gauge 4.      Checking the smoothness of the finished RCC surface with a straight edge 5.      Core sampling from the compacted RCC for measurement of Density, Strength and Thickness 6.      Fabricating RCC cylinders or cubes and beams for Strength Tests.

Quality Control / Assurance of RCC at construction site and in laboratory

Page 52: RCCP Presentation

 

1. RCC mixture has a lower water content and the water cement ratio is typically around 0.35. Due to its low water content ratio, RCC mixture typically has high strengths similar to or even greater than conventional concrete.

2. Low water content and Low Water / Cement ratio increases Strength, Reduces Permeability, Enhances Durability and Resistance to Chemical Attack.

3. Aggregate interlock feature of RCC provides High Shear Strength at joints and un-controlled cracks to prevent vertical displacement or faulting.

Advantages of using Roller Compacted Concrete in Road Pavement Constructions

Page 53: RCCP Presentation

4. Low water content allows RCC mix to be compacted by using 8 Ton vibratory rollers.

5. RCC Pavements do not need either formworks or surface finishing.

6. It does not use either dowel bars or steel reinforcing.

7. Typically RCC Pavement is constructed without joints.

8. Commonly available Machines and Equipments used for conventional asphalt concrete pavement construction. 

9. Due to its advantage as a comparatively low cost, durable paving material, RCC Pavement Technology has becoming popular in Road Constructions.

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THANK YOU