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RCC ROLLER COMPACTED CONCRETE

1.0 INTRODUCTION
1.1 Definition
RCC is generally defined as a no-slump concrete that is placed by earth-moving equipment and
compacted by vibrating rollers in horizontal lifts up to 12 inches thick (United States. Bureau of
Reclamation. 1987)
Roller-compacted concrete, or RCC, takes its name from the construction method used to build it. It's
placed with conventional or high-density asphalt paving equipment, and then compacted with rollers.
RCC has the same basic ingredient as conventional concrete: cement, water, and aggregates, such as
gravel or crushed stone.
But unlike conventional concrete, it's a drier mixstiff enough to be compacted by vibratory rollers.
Typically, RCC is constructed without joints. It needs neither forms nor finishing, nor does it contain
dowels or steel reinforcing.
These characteristics make RCC simple, fast, and economical
1.2 Background
RCC or Roller compacted concrete was limited to the sub-base of roads and airfield pavements and
concrete dams, being called lean concrete or dry lean concrete. RCC became popular due to the fact that it
is a simple material to produce and place. RCC (Rolled Compacted Concrete) has low cement content,
about 110 to 120 kg/m3, and uses washed aggregate of concreting quality. American Concrete Institute
(ACI) 207.5R-89 defines roller compacted concrete (RCC) as concrete compacted by roller compaction.
RCC got its start in the Seventies During all the worlds especially in United State of Amerce and Canada.
Roller compacted concrete constitutes the same basic ingredients of cement, fine and coarse aggregates
and water. But unlike the conventional concrete RCC is a drier material that has the consistency and feel
of damp gravel. RCC attains its high-strength properties since it has low water-cement ratio and the use of
dense graded aggregates.(Piggot 1999)
The use of RCC is more economical as result of the method of production and ease with which its used in
construction. RCC does not require joints, dowels, reinforcement steel, formwork or finishing its
virtually maintenance free.
1.3 Typical application areas
1. Road construction
For road construction the mix is placed through a conventional or a high-density paver and
similar to asphalt, is then compacted with a vibratory roller. RCC is also much stronger than
asphalt and can be placed thinner to achieve the desired load carrying capability. This labor and
thickness reduction combined with the competitive initial material cost compared to asphalt
makes RCC extremely cost effective. RCC will not have any potholes, rutting, or shoving and can
span soft localized soft sub grades. RCC will not deform under heavy concentrated loads and will
not soften under high temperatures. Builders offers a base mix which works great for base and

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 binder asphalt replacement and can be surfaced with asphalt if desired. Surface mix design which
is made up of smaller aggregates for enhanced smoothness is provided.
2. Dam construction
RCC has three key properties that make it uniquely suited for dams: economy, performance, and
high-speed construction. It has the strength and durability of conventional concrete, but at a cost
that rivals earth or rock fill construction.

RCC can be used to build new dams or to shore up old ones. It protects dams from over-topping
failure, earthquakes, and erosion.

It can be placed quickly and easily with large-volume earth-moving equipment. It's generally
transported by dump trucks, spread by bulldozers, and compacted by vibratory rollers. Sections
are built lift-by-lift in successive horizontal layers so the downstream slope resembles a concrete
staircase. Once a layer is placed, it can immediately support the earth-moving equipment to place
the next layer. After RCC is deposited on the lift surface, small dozers typically spread it in thick
layers. Workers also place it with motor graders, spreader boxes, and paving machines

3. Other areas of application

i. Bulk material storage
ii. General cargo storage
iii. Container terminals
iv. Road / rail transfer facilities
v. Ro-Ro terminals
vi. Truck parks
vii. Tank roads and parking
viii. Sewage sludge stacking
ix. Composting slabs
x. Pre-casting yards

1.4 Properties of RCC mixes

The stiffness consistency of RCC and the use of densely-graded aggregate blends raise the main
differences from the conventional concrete hence yielding the following properties

It has lower water content

Has a lower paste content
Does not typically incorporate fibers
RCC is not typically air-entrained but some admixtures can be added
It has smaller maximum aggregate size.

1.5 Benefits
1. Supports heavy, repetitive loads without failure and spans localized soft subgrade areas,
which reduces maintenance costs and down time.
2. Withstands high concentrated loads and impacts from heavy industrial, military, and mining
applications.
3. Eliminates rutting and subsequent repairs.

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 4. Provides excellent durability, even under freeze-thaw conditions; eliminates seepage through
pavement.
5. Increases strength, reduces permeability, and enhances durability and resistance to chemical
attack.
6. Provides high shear resistance at joints and uncontrolled cracks to prevent vertical
displacement or faulting.
7. Speeds and simplifies construction, reduces costs.
8. Speeds construction, reduces cost, and minimizes labor.
9. Speeds construction, reduces cost. (To enhance appearance, joints can be sawn into RCC
pavement.)
10.Resists abrasion, eliminates need for surface course and reduces cost. The light color
reduces lighting requirements for parking and storage areas
1.6 Limitations
1. Aesthetics - RCC does not have the same appearance as other types of concrete. It is
NOT as pretty and smooth as regular concrete.

2. Rougher Surface Texture - The mix design and construction methods that make roller
compacted concrete so fast, easy, cheap, and durable also create a surface texture that
gives it a characteristic coarse finish.

3. Limited to low-speed traffic - Due to the nature of its surface, RCC is not appropriate for
all types of traffic. Vehicles traveling at high speeds would experience a bumpy ride.
That makes it better for applications where strength and durability are needed instead of
speed.

4. Leakage may happen in Dams Due to the nature of its surfaces and the way of the
constructions layer bay layers in the dams leakage of water may be happen and
treatments are needed in the ends extra cost may be needed.

1.7 Characteristic Features of RCC

1. High flexural strength (500 to 1000 psi) (3.5 MPa to 7.0 MPa)
2. High compressive strength (4,000 to 10,000 psi) (28 MPa to 69 MPa)
3. High shear strength
4. High density, low absorption
5. Low water content, low water/cement ratio
6. Aggregate interlock
7. No steel reinforcing or dowels
8. No forms or finishing
9. No formed or sawed joints
10. Hard, durable, and light colored surface

2.0 MATERIALS

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The intended use of RCC dictates the materials to be used, the project specifications must clearly state the
material requirement that will meet the design and performance objectives.
2.1 Aggregates
This constitute both coarse and fine aggregates and are well blended. Coarse aggregates consist of
crushed or uncrushed gravel and fine aggregates consist of natural sand or any other form of fine
aggregates. Due to sharp interlocking edges of the aggregate particles crushed aggregates produce a better
RCC mix.
The American concrete institute (ACI) has established aggregate gradation limits that produce quality
RCC mixtures. These ACI gradation limits effectively allow the use of blends of standard size coarse
aggregate. From ASTM C 33, the most common sizes used include No. 67, No.7, No.8, and No.89.
ACI and the Portland Cement Association (PCA) recommend the use of dense, well-graded blends with
nominal maximum size aggregate not exceeding 1-inch (25mm) in order to help minimize segregation
and produce a smooth finished surface. Gap-graded mixes that are dominated by two or three aggregate
sizes are not desirable for RCC. Additionally, the recommended gradation calls for a content of fine
particles (2% to 8% passing the No. 200 sieve). This eliminates the need for washed aggregates in many
cases and produces a mix that is stable during rolling.

2.2 Cementitious Materials

The selection of type and amount of cementitious materials should be based on the availability as well as
the required design strength and durability of the finished RCC. These cementitious materials include
cement and Pozzolan Type I, Type IP, or Type II Portland cement (ASTM C 150), blended hydraulic
cement (ASTM C 595), Class F or C fly ash (ASTM C 618), silica fume (ASTM C 1240) and ground
granulated blast furnace slag (ASTM C 989, or CSA A3001 for all cementitious materials)
2.3 Admixtures
Chemical admixtures used in RCC must conform to ASTM C 494, and there should always be approval
prior to their usage.
Some of the admixtures most commonly used are water-reducing or set-retarding admixtures used when
there is a long haul time between the production point and the project time, Set-accelerating admixtures
are used when the purpose is to speed up setting this is done when the project is entirely time dependent.
2.4 Water
The water to be used should be of good quality devoid of any deleterious material. Water to total
cementitious ratio expressed as W/(C+P) generally lies between 0.30 and 0.45, Water cementitious ratio
in this range have greatest positive influence on the final strength of the RCC, with 28-day unconfined
compressive strengths exceeding 6,000psi.

3.0 MIX DESIGN

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In order to produce a good quality RCC mix, a systematic procedure based on the aggregates, water and
cementitious materials is used in the mix.
There exists a number of design mix methods the accepted common methods include
3.1 Proportioning by use of Concrete consistency testing
This method uses consistency of the individual ingredients, consistency tests normally require the
establishment of specific mixture parameters-such as the amount of aggregate, the amount water, or the
amount of cementitious materials then adjust one of these parameters in order to meet the required
consistency, workability, or strength.
3.2 Proportioning by use of the solid suspension Model
This proportioning method is used to determine the proportions of each of the dry solid ingredients
(cement, fly ash, silica fume, sand and coarse aggregate) that optimizes the dry packing density of a given
RCC mixture. Using this optimized dry packing density, the amount of water necessary to entirely fill the
void spaces between the dry ingredients can easily be calculated.
The main advantage of the solid suspension model is that it can be used to recalculate very quickly the
optimum proportions of RCC mixture without having to prepare a large number of laboratory trial
batches. (Marchand 1997)
3.3 Proportioning by use of the optimal paste volume method
Because the workability of an RCC mix is one of its main requirements, this method stresses a mix design
that will meet specified workability requirements. It is based on the assumption that an optimal mix
should have just enough paste to completely fill any remaining voids after the aggregates have reached
their maximum density under compaction.
The optimal paste volume method has three major steps. The first step is to select an aggregate gradation
that contains a minimal volume of voids for a given compaction energy. In the second step, the volume of
remaining voids is used to adjust the volumetric dosage of paste in order to obtain the required
workability. The third and final step involves the selection of the W/(C + P) ratio and the proportions of
cement and any other cementitious materials that will produce a paste with enough binding capacity to
satisfy the strength requirements of the project. (Gagne 1999)
3.4 Proportioning by use of soil compaction tests
This proportioning method involves establishing a relationship between the density and moisture content
of an RCC mix by compacting samples over a range of moisture contents as described in the section of
this document titled Moisture-Density Relationship. Moisture-density tests are conducted and moisture-
density curves are established over a range of cementitious material contents. Strength test specimens are
then prepared by compacting specimens at the optimum moisture content for each particular cementitious
material content. From these tests, a plot of strength versus cementitious material content is established to
select the minimum cementitious materials content that will meet the design requirements (ACI 2004)

3.5 Moisture-Density Relationship

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A moisture-density test is used to determine the optimum moisture content and maximum density of RCC
mixtures. The modified Proctor compaction test (ASTM D 1557) is a common and familiar procedure for
most geotechnical and materials testing laboratories to perform.

Figure 1: Typical Moisture Density curve for RCC mixes

4.0 PRODUCTION
4.1 Mixing equipment
There various kind of equipment used in the production of RCC though these depend on the magnitude
and nature of the project.
Transit Mixers
These are tailored for small scale production since they have slower mixing and discharge times.
Tilt Drum mixers
By far the most common central mixing unit, tilt drum mixers (either portable or permanent) have
regional availability coupled with fast, quality-consistent production capabilities, making them
suitable for most RCC projects
Mobile Truck mixers
Versatility and speed are advantages of mobile truck mixers since all componentsaggregates,
cement, and waterare stored in separate compartments on the truck unit

Horizontal Shaft Mixers

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 Whether single-shaft or dual-shaft, portable or permanent, continuous flow (as in a pug mill) or
compulsory batch, spiral ribbon or paddle, horizontal shaft mixers provide the most intense and
fastest mixing action, making them the best choice for larger and high production-oriented
projects.

Figure: Stationary tilt drum mixer Figure: Mobile truck mixer

Figure: Continuous flow pug mill mixer Figure: Portable horizontal shaft mixer

4.2 Batching and mixing

Whichever mixing method is employed, it is imperative that RCC be mixed vigorously in order to evenly
distribute the small amount of water present in the mix. Because of its zero-slump and low paste content,
the key to producing a strong, durable RCC mix rests in the careful proportioning and vigorous mixing of
all the ingredients
Table 1: Recommended mixing times and batch sizes for RCC (PCA 2002)

5.0 TRANSPORTATION

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Regardless of the mixing and batching method chosen, the RCC mix is almost always transported to the
job site in dump trucks. These dump trucks should be equipped with covers in order to protect the RCC
mix from the elements and to ensure efficient placement. While RCC can be produced directly into dump
trucks from tilt drum and horizontal shaft mixers, the use of transit mixers involves the additional step of
discharging into a dump truck for delivery. Because of the very dry consistency of RCC, the use of
fluidizing admixtures is recommended when mixing or hauling RCC in transit mixers

Figure : RCC loaded into truck for delivery to project

6.0 APPLICATION
6.1 Placing and spreading
Spreading of RCC is commonly done by a dozer. The RCC is spread to the loose lift thickness which is
able to produce a final lift thickness of 12inches after compaction. Its important that within 45minutes
the RCC should be transported, deposited and compacted.
6.2 Compaction
To obtain the required strength and density, proper compaction and consolidation is required. The lift to
be compacted should not be exceed 12inches otherwise the lower layer will not receive proper
compaction.
During this process continuous tests for density are carried out to ensure that the required compaction is
attained.
Compaction should be done as soon as the RCC is placed and spread. When RCC approaches full
compaction, the concrete should exhibit slight plasticity as the roller passes over the RCC surface this is
also an indicator of workability.

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6.3 Lift surface preparation
Lift surface preparation is important especially in providing bond between the lifts. There are various
reasons for ensuring proper bond

The need to develop some tensile strength during earthquakes

The need to minimize water seepage through the lift lines
Uplift pressures preventing RCC section from meeting stabilizing safety factors
Sliding resistance for normal and unusual loads

6.4 Curing and protecting

The compacted RCC should be cured continuously but it should be done in such a way that the W/(C+P)
ratio is not affected.
6.5 Tests
For purposes of quality control a number of tests have to continuously carried out these include
compressive strength (ASTM C 39), consolidation test (ASTM C1170-91), Elasticity properties/modulus
of elasticity/poisons ratio (ASTM C 469), Density test, Thermal properties, durability, workability,
consistency test and Segregation potential

7.0 CONCLUSION
The advent of roller compacted concrete has greatly reduced the project time, cost and improved
performance of the structures constructed. This makes use of RCC more economical as a result of the
simplified method of production and application which are cost and time saving.

7.0 REFERENCES
1. ACI (2004). Manual of Concrete Practice. Roller Compacted Concrete
2. Gagne, R. (1999). "Mixture Proportioning of Non-Air-Entrained RCC for
Pavements." Concrete international 21(5).
3. Marchand, J., Gagne, R., Lepage, S., and Ouellet, E., (1997). Mixture
proportioning of Roller - Compacted Concrete for Dams and Pavement
Construction. Third CANMET/ACI International Symposium on Advances in
Concrete Technology.
4. PCA (2002). "Design and Control of Concrete Mixtures." Portland Cement
Association.
5. Piggot, R. W. (1999). "Roller-Compacted concrete Pavements-A Study of Long
Term Performance." Portland Cement Association RP366.
6. United States. Bureau of Reclamation. (1987). Design of small dams.
Washington, D.C., U.S. Dept. of the Interior For sale by the Supt. of Docs., U.S.
G.P.O.

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