Roller Compacted Concrete (RCC) in Pavements ..

the UK Experience

Kostas Koutselas Research Manager Aggregate Industries UK Research & Development Department

Aggregate Industries Ltd. 2008

Technical Seminar, EcoLanes Fifth Management Meeting, Paphos, Cyprus, 8 April 2009

Roller Compacted Concrete Company (RCCC)

Sitebatch Technologies - Mix

Design and Mixing

Needham & Cullen - Paving Aggregate Industries

Aggregate Industries Ltd. 2008

Technical Seminar, EcoLanes Fifth Management Meeting, Paphos, Cyprus, 8 April 2009

What is Roller Compacted Concrete?

RCC takes its name from the construction method used Laid by tracked asphalt paver equipped with heavy duty dual tamping screed d and d compacted t d with ith rollers ll Same constituent materials as conventional concrete (cement (cement, aggregates and water) Produced in a high output continuous mix plant Formwork is not normally required Crack control is by y induced cracking g
Aggregate Industries Ltd. 2008

Technical Seminar, EcoLanes Fifth Management Meeting, Paphos, Cyprus, 8 April 2009

What is the performance of Roller Compacted Concrete?

Strength and durability of Pavement Quality Concrete May provide final running surface Surface finish similar to fine rolled asphalt Suitable for low speed environment Requires surfacing for high speed roads Requires surfacing in airfield applications

Aggregate Industries Ltd. 2008

Technical Seminar, EcoLanes Fifth Management Meeting, Paphos, Cyprus, 8 April 2009

Constituent Materials
Aggregate - Good quality crushed rock preferred

High 10% fines value Los Angeles Coefficient C ff LA40 Specific dense grading PSD needs to be consistent and tightly controlled

Cement - Relatively low cement content

approx 12 12.5% 5% PC / PFA blend gives long term strength gain

Water - Potable

Low target moisture content Typically 6%

Aggregate Industries Ltd. 2008

Technical Seminar, EcoLanes Fifth Management Meeting, Paphos, Cyprus, 8 April 2009

Specification - Standard UK practise adopted

Specification for Highway Works Series 800 covers mixing, laying, rolling and jointing activities Concrete C t strength t th to t BS8500, BS8500 typically t i ll C32/40 Testing of strength & Density to Clause 870 of SHW 5 samples per 1000m Cubes tested in compression at 7 and 28 days In-situ density verified by NDM Optional additional testing compressive strength at 56, 90 & 365 days Flexural strength beams taken to verify laboratory trials

Aggregate Industries Ltd. 2008

Technical Seminar, EcoLanes Fifth Management Meeting, Paphos, Cyprus, 8 April 2009

Equipment
Continuous mix plant Transport trucks Heavy duty asphalt paver Rollers vibratory, PTR

Aggregate Industries Ltd. 2008

Technical Seminar, EcoLanes Fifth Management Meeting, Paphos, Cyprus, 8 April 2009

Method - Mixing

RCC is usually produced in a continuous mixing plant set up on site, enabling good control over p g product q quality y and continuity y of supply pp y to the p paver. Supply pp y from Ready Mix plant is also possible depending on contract
Aggregate Industries Ltd. 2008

Technical Seminar, EcoLanes Fifth Management Meeting, Paphos, Cyprus, 8 April 2009

Method - Paving
Paver laid High compaction dual tamping screeds Crack control joints installed mechanically Disciplined rolling to ensure good compaction

Aggregate Industries Ltd. 2008

Technical Seminar, EcoLanes Fifth Management Meeting, Paphos, Cyprus, 8 April 2009

Highway Paving
Full width paving up to 12m in

one pass
Thickness of up to 300mm in

one lift

Aggregate Industries Ltd. 2008

Technical Seminar, EcoLanes Fifth Management Meeting, Paphos, Cyprus, 8 April 2009

Testing
Pavement performance is heavily influenced by the degree of compaction of the RCC and every effort is made to achieve the maximum density The site testing regime includes NDMs, cubes and control beams

Aggregate Industries Ltd. 2008

Technical Seminar, EcoLanes Fifth Management Meeting, Paphos, Cyprus, 8 April 2009

Current Applications in UK
Truck & Trailer Parking Container Storage & Handling Materials Storage & Handling Waste Processing Hardstandings Composting Hardstandings Heavy y Industrial Access Roads Farm Roads Port Pavements

Aggregate Industries Ltd. 2008

Technical Seminar, EcoLanes Fifth Management Meeting, Paphos, Cyprus, 8 April 2009

Applications in Highways
USA - Freeway Hardshoulders; Urban low speed roads. No

surfacing
Canada Urban intersections and heavily trafficked routes, with

surfacing
Spain S i Medium M di and dh heavily il t trafficked ffi k d roads d with ith asphaltic h lti surfacing, f i

reflective cracking effectively controlled

Aggregate Industries Ltd. 2008

Technical Seminar, EcoLanes Fifth Management Meeting, Paphos, Cyprus, 8 April 2009

Future Applications in UK
AIRFIELDS

Will require surface course Advantage of low cost, high flexural strength concrete
HIGHWAYS

Under consideration, with induced cracking and binder/surface courses, for bus lanes, truck lanes, motorway widening and as an alternative to fully flexible pavements

Aggregate Industries Ltd. 2008

Technical Seminar, EcoLanes Fifth Management Meeting, Paphos, Cyprus, 8 April 2009

Further Information
USA Portland Cement Association website

www.cement.org/pavements
Carlos Jofr Spanish Institute of Cement, Madrid kostas.koutselas@aggregate.com john.donegan@aggregate.com

Aggregate Industries Ltd. 2008

Technical Seminar, EcoLanes Fifth Management Meeting, Paphos, Cyprus, 8 April 2009