MATERIALS AND RCC QUALITY REQUIREMENTS

MATERIALS AND RCC QUALITY REQUIREMENTS

Andriolo, Francisco Rodrigues

ANDRIOLO ITO ENGENHARIA SC LTDA

Rua Cristalândia 181- Alto de Pinheiros
05465-000- São Paulo- Brazil
www.andriolo.com.br; [email protected]

ABSTRACT: This presentation is composed of 4 Parts: Materials, RCC Mix Proportions, Tests and Properties,
Inspection and Quality Control. The part referring to Materials mentions the ample scenery open by the RCC
Methodology for the best use of the materials available. The Mix Proportion discuss a routine for RCC mix
design.
The Tests and Properties Part exposes in a comparative way the CVC and RCC Properties. The text
about Inspection and Quality Control presents information about the RCC control in several jobs. We are trying
through these two topics to evidence that the RCC is a CONCRETE, leaving no doubts about its performance.

1 MATERIALS mesh with a “d” opening and “Dmax” the maximum

size of the aggregate with the major dimension used
1.1 General in the mixing.
Observing the curves in Figure 01 one can see
Roller Compacted Concrete (RCC) is a CONCRETE, that as the aggregates Dmax in the grading
but differs from traditional concrete principally in that composition is reduced, a greater quantity of “sand”
it has a consistency that will support a vibratory roller (material inferior to 5mm) is required, as well as a
and an aggregate grading and proportion suitable for greater quantity of “fines“ (material inferior to
compaction by such a roller. 0,075mm). These conditioning items are required so
The objective of the selection of the materials that you can have closed grading concrete (RCC),
for and design of the mixture proportions of an RCC with a smaller number of air voids, therefore with a
is to provide a stable concrete that meets all the in-situ maximum density and lower permeability.
properties as strength, durability, and permeability The availability of natural materials with
requirements of the structure. When considering the grading near optimum (curves in Figure 01) implies
materials (and mixture proportions) for an RCC dam, the need to process the aggregates, in order to attend
the Designer must always bear in mind that it is the the grading curve. In that situation, it is common the
in-situ properties, including those at the horizontal need of not only doing the sieving but also crushing
joints between the layers, the “over size” fractions so that the desired grading
that are important and not the properties that might be can be attained. Here attention is called to the content
achievable in the laboratory. of “fines” desirable in the RCC mixes. The
Materials for RCC can be from pit-run unavailability of “fines” will lead to the need of
minimally processed aggregates with low adopting an alternative to “close” the grading and
cementitious (cement plus mineral admixture) minimize the air voids. This can be obtained by using
contents to fully-processed concrete aggregates with pozzolanic material (if available at a low cost) either
different cementitious contents. of Silt or of Rock Flour. The choice of the alternative
must be made, prudently, on a technical and
1.2 Aggregates economical basis.
The majority of RCC dams have been
1.2.1 General constructed with aggregates meeting all of the
traditional concrete requirements.
The selection of aggregates and control of aggregate The presence of any significant quantity of
grading are important factors influencing the in-situ flat and/or elongated particles is usually undesirable.
quality and properties of RCC. The variability of However, RCC mixtures appear to be less affected by
aggregates during construction significantly affects these particles than traditional concrete mixtures. This
the cementitious and water requirements, which in peculiarity may be because the compaction equipment
turn affect strength and yield. As the RCC is a provides more energy than traditional consolidation
concrete the Specifications should reflect an methods and because the higher mortar content tends
appropriate degree of control of aggregate quality and to provide more separation of coarse aggregate
grading. The aggregates grading composition curve particles, and the fact that the water content in RCC
more often used in the RCC works has been of the has not the same concept as in the CVC related to
cubical type as p= (d/Dmax)1/3 *100% type, with workability.
“p” being the percentage of a material finer han the
 Field tests with up to 40% flat and elongated aggregate within the total grading can reduce the
particles (with an average below about 30%) have tendency for segregation.
shown to be no significant problem[1]. The US Army The most popular maximum size is in the 75-
Corps of Engineers currently has a limit of 25% on to 80- mm size, although there now seems to be a
the allowable content of flat and elongated particles trend towards smaller sizes because of the problem of
[2]. segregation. The maximum size is tending towards 50
Aggregate Composed Grain Size Curve - RCC MSA (75; 65; 50; 38) mm to 60 mm. The maximum size of aggregate is not
100 related to layer thickness nor compaction machinery.
90 Compactability is governed primarily by the
80
workability of the concrete.
Percent Passing (%)

70
60
50 MSA - Dmax 75mm 1.2.3 Fine Aggregate
40 MSA - Dmax 63mm
30 MSA - Dmax 50mm
20 MSA - Dmax 38mm Gradings of fine aggregate conforming to traditional
10 concrete limits[3] have been successfully used for
0
75 63 50 38 32 25 19 16 12,5 9,5 4,8 2,4 1,2 0,6 0,3 0,15 0,08
most RCC dams. Fine aggregates with these gradings
Grain Size (mm) may occasionally require more cementitious material
Aggregate Composed Grain Size Curve - CVC MSA (75; 65; 50; 38)
than is needed for lean mixtures using aggregate with
mm more fines than is generally allowed.
100
Unwashed aggregates with a much broader
90 grading range than is usually specified[3] have also
80 been used. The aggregate grading and fines content
Percent Passing (%)

70
60 affects the relative compactability of the RCC and
50 MSA - Dmax 75mm may influence the minimum number of vibrating
40 MSA - Dmax 63mm
30 MSA - Dmax 50mm
passes required for full consolidation of a given layer
20 MSA - Dmax 38mm thickness. It also affects the water and cementitious
10
0
material requirements needed to fill the voids in the
75 63 50 38 32 25 19 16 12,5 9,5 4,8 2,4 1,2 0,6 0,3 0,15 0,08 aggregate and coat the aggregate particles. Crusher
Grain Size (mm)
fines and silty (no-plastic fines) material are usually
Figure 01- Usual Aggregates Grain Size Curves for acceptable.
RCC and CVC
1.2.4 Overall Grading
Where there is a choice of source material, the
material with the best combination of physical As can be seen in Figure 01 there is a definite trend of
properties should be selected. Apart from the need for a reduction in fine aggregate content with increasing
hard, durable aggregate, of high unit weight, maximum size of aggregate. Some cost savings might
characteristics that affect the thermal characteristics be achieved by combining two or more size ranges to
and cracking of the dam are important. A low elastic reduce the number of stockpiles. The Designer and/or
modulus and low coefficient of thermal expansion are Contractor must balance the potential cost savings in
desirable. a reduction in number of stockpiles and separate
handling and weighing facilities with the potential for
1.2.2 Coarse Aggregate increased variation in aggregate grading and its
impact on uniformity of the RCC. Three or four
The most important factor to consider when selecting aggregates sizes are mostly used in RCC dams.
the source, shape and grading of a coarse aggregate is
the avoidance of segregation. No matter how good the 1.2.5 Gravel or Crushed Aggregates
theoretical properties of an RCC are, if that concrete
segregates when it is transported, spread and
compacted, the in-situ performance will be less
satisfactory than expected. In order to avoid
segregation, it has been found that a well-graded
aggregate, and with low amount of the coarsest
fraction is more satisfactory. The maximum size of
aggregate can have a very significant effect on
segregation. Generally, the smaller the maximum size
the less will be the tendency to segregate. However
the additional effort required to produce aggregates
with a smaller maximum size has to be balanced
against the need to avoid segregation. It has been
found that an increase in the proportion of the fine Figure 02- Natural Aggregates
The RCC can be proportioned and compacted with crushing rocks with certain amount and mineralogical
natural aggregates (gravel) or with crushed condition of siliceous matrix. Even if these two last
aggregates. The most important item is that the materials are generally less effective than other types
aggregates be proportioned adequately and the of materials, they have been used in RCC for dams,
admixtures comply with the properties, at a low cost. particularly in Brazil [5 & 6], and some other
countries [7].
1.3 Cementitious Materials Use of mineral admixtures or fillers in RCC
mixtures may serve one or more of the following
1.3.1 General purposes:

RCC can be made with any of the basic types of ƒ as a technical purpose to minimize the Alkali-
cement or, more usually, with a combination of Aggregate Reaction;
cement and a mineral admixture. It is very well ƒ as a proportion of the cementitious content to
known that the great majority of RCC mixtures reduce heat generation;
contain mineral admixtures (usually a ground- ƒ as an additive to provide supplemental fines for
granulated blast-furnace slag, fly-ash, natural mixture workability, and impermeability, and
pozzolan, rock flour and silt). The use of mineral ƒ as a proportion of the cementitious content to
admixtures has the desirable effects of reducing the reduce cost.
Portland cement content, thus usually lowering costs
and reducing the heat of hydration, and giving slower Natural
strength development which can reduce thermal Pozzolan
stresses. Calcined
Clay
1.3.2 Cement
Fly
Ash
RCC can be made from any of the basic types of Mineral
cement. For RCC dams, cements with lower heat Admixtures Granulated Blast
generation characteristics than Ordinary Portland Furnace Slag
cement (ASTM C150 [4] Type I) may be beneficial, if
they are locally available. They include Type II Silt
(moderate heat), Type IP (Portland pozzolan cement),
Rock
and Type IS (Portland blast-furnace slag cement).
Flour
Strength development for these lower-heat cements is
Figure 03: Forms of mineral admixtures
usually slower than for Ordinary Portland cement at
early ages. At greater ages, the slower-early-strength-
The convenience of adopting the cubic type of
development cements usually ultimately produce
grading curve as previously mentioned, implies in
higher strengths than Ordinary Portland cements.
having around 10 to 15% of fines (material inferior to
0.075mm), as shown in Figure 01. In order to do that
1.3.3 Mineral admixtures
it is possible to rely on the use of “Silt”, obtained in
natural deposits or by the production of fines using
Mineral admixtures are finely divided siliceous
rock crushing, gravel or blast furnace slag. In these
materials that are added to cement. The use of
cases the rock crushing, producing the Rock Flour,
pozzolanic materials in the massive concretes is an
may be even more beneficial, if, besides composing
old and renowned practice, with the use of
the desired grain curve, the rock has contents and
percentages around 15 and 25%, predominantly. The
mineralogical conditions (SiO2; Al2O3 and Fe2O3) that
advent of RCC led to the use of higher contents of
have satisfactory pozzolanic activities.
pozzolanic materials. In a special range the blast-
The indiscriminate and irrational use of high
furnace slag can be placed, which also presents
contents of pozzolanic material is not advisable under
pozzolanic characteristics.
two aspects:
Some mineral admixtures can show
ƒ The occasional unavailability of Calcium
pozzolanic activity (fly ash, natural pozzolan and
composites, present in the Cement, to react fully
calcined clay- Figure 02), some others are
with the components of the pozzolanic material.
cementitious (ground-granulated blast-furnace slag),
ƒ Costs
whereas others are both cementitious and pozzolanic
This is to say that the adequate content of Pozzolanic
(high-lime fly ash).
material to be used depends on the Pozzolanic
Prior testing of potential sources of
Activity, to be shown together with the cement, in
pozzolanic material in the RCC mixture is advisable
tests with different combination contents of cement:
for all structures. If no other source of mineral
pozzolanic material.
admixtures is available, it is possible to obtain a
certain pozzolanic activity using a siliceous filler by
 A good example about this evaluation can be The use of pozzolanic material has made the
observed in Japanese [8 & 9], Chinese [10], and designer revise the properties control age, which
Brazilian [5, 6 & 11], studies, where it is evidenced: around the sixties was between 28 and 90 days, with
ƒ The Japanese studies - “…As a result, it became very few countries using the ages of 180 days and one
clear that by mixing the filler of proper quantity, the year, to the present situation where the properties
VC value (Vibrating Compacting Value) of concrete began to be controlled mainly with more than 90
quantity dropped, and compacting became easy, and days.
compressive strength was increased. Moreover it is The use of high contents makes part of the
thought that the use non-washing crushed stone is pozzolanic material act as “Filler” and this must be
possible…”(See graphics in Figures 04 & 05); economically evaluated (as mentioned before).
ƒ The Chinese studies - “…The optimum content of
Fly Ash should be determined according to the quality
of Fly Ash, strength and strength design age of
concrete, variety and strength grading of cement,
price ratio of cement to Fly Ash and so on…”(See
graphics in Figures 06);
The Brazilian studies – “…Improved resistance
obtained with the use of Filler on the CVC, plus the
improvement observed in reduction of the RCC
permeability prove that the use of this material is
worthwhile…”[12]; “…Pozzolanic Activity Indexes
with various cements have proved to grow according
to the age and Fineness (Blaine) of the incorporated
Fillers; Fillers tested have demonstrated a substantial
efficiency to reduce the expansions resulting from the
Alkali-Silica Reaction thus demonstrating another
important pozzolanic action; The set of data
submitted in this report makes evident a substantial
Figure 05- Compressive Strength of RCC Versus
Pozzolanic characteristic of the Fillers studied which
Age with Different Fly Ash Replacement Ratios;
states the validity of its use in RCC and also in
and with different cement type (From [9])
conventional types of concrete which corroborates the
theoretical expectation mentioned in the text…” [5]

Figure 06- Compressive Strength curves for

mortar with different Fly Ash contents and
different types of Fly Ash (From [10])

Figure 04-Compressive Strength and Vibrating 1.4. Admixtures

Comapcting Value with different Fines Content
(From [8]) The use of additives in RCC is a relatively new
approach. The use of chemical additives has increased
since mid 90’s, aiming at controlling the “Set” and
broadening the operational margin for RCC
transportation and compaction [13 to 17]. Its use has
propitiated, besides control of the set, gains in
resistant properties and that becomes a technical
parameter with economic implications that must be
analyzed (see Figure 09). The choice of any
admixture should be confirmed by laboratory trial
mixes and ideally after full-scale trials. Particular
admixtures work well with particular cementitious
materials and not so well with other materials.
Figure 07-Reduction of the Mortar Expansion due
to the Use of Rock Flour (From [5])
Mortar Test Sample as produced - Blaine Sample grinded - Blaine 4,024
Control 2,962 cm2/g cm2/g
Fly Ash Content (%) 0 10 15 20 30 10 15 20 30
e Strength

7 days 209 166 159 139 107 205 192 172 116
Compressiv

(kgf/cm2)

28 days 331 254 243 233 169 319 318 282 199
90 days 397 342 352 327 279 433 423 420 308
365 days 426 435 471 472 389 548 538 537 466
Heat of 7 days 76 63 60 63 52 68 64 61 62
Hydration 28 days 80 74 72 72 68 83 73 73 73
( l/ )
28 days 100% 83% 82% 78% 60% 93% 105% 93% 66%
Strength
Activity:

/ Heat

90 days 100% 93% 99% 92% 83% 105% 117% 116% 85%
365 days 100% 110% 123% 123% 107% 124% 138% 138% 120%
Mortar Test Sample grinded - Blaine 5,200 Sample grinded - Blaine 6,056 Sample grinded - Blaine 7,142
cm2/g cm2/g cm2/g
Fly Ash Content (%) 10 15 20 30 10 15 20 30 10 15 20 30
e Strength

7 days 237 211 188 155 238 198 163 152 226 205 214 169
Compressiv

(kgf/cm2)

28 days 351 325 296 253 365 339 303 298 391 372 377 345
90 days 436 421 428 413 479 452 455 477 450 481 500 502
365 days 559 563 548 579 557 553 566 583 551 569 569 605
Heat of 7 days 68 65 61 57 64 62 59 60 68 66 63 56
Hydration 28 days 76 74 70 71 73 74 75 71 78 78 70 70
( l/ )
28 days 112% 106% 102% 86% 121% 111% 98% 101% 121% 115% 130% 119%
Strength
Activity:

/ Heat

90 days 116% 115% 123% 117% 132% 123% 122% 135% 116% 124% 144% 145%
365 days 138% 143% 147% 153% 143% 140% 142% 154% 133% 137% 153% 162%
Pozzolanic Activity: Strength/Heat - Fly Ash Samples - Raw
Pozzolanic Activity: Strength/Heat - Fly Ash Samples - Grinded
Material Blaine -2,962 cm2/g
Blaine-4,024 cm2/g
130% 150%

120% 140%

130%
110%
120%
Activity (%)

Activity (%)

100% 110%

90% 100%

90%
80%
28 days age 80% 28 days age
70% 90 days age 90 days age
70%
365 days age 365 days age
60% 60%
10 15 20Fly Ash % Replacement
30 10 15 20 30
Fly Ash % Replacement

Pozzolanic Activity: Strength/Heat - Fly Ash Samples -

Grinded Blaine-5,200 cm2/g
160%
150%
140%
130%
Activity (%)

120%
110%
100%
90%
28 days age
80%
90 days age
70%
365 days age
60%
10 15 20 30
Fly Ash % Replacement

Pozzolanic Activity: Strength/Heat - Fly Ash Samples - Pozzolanic Activity: Strength/Heat - Fly Ash Samples - Grinded
Grinded Blaine-6,056 cm2/g Blaine-7,142 cm2/g
160% 180%

150%
160%
140%
130% 140%
Activity (%)
Activity (%)

120%
110% 120%
100%
100%
90%
28 days age 28 days age
80%
90 days age 80% 90 days age
70% 365 days age 365 days age
60% 60%
10 15 20 30 10 15 20 30
Fly Ash % Replacement Fly Ash % Replacement

Figure 08- Compressive Strength of Mortar with different contents of Fly Ash at different
Fineness (from [11])
 A number of mixture proportioning methods
Coefficient of Variation - Comparison
16
have been successfully used for RCC structures
throughout the world. Projects have differed
14
significantly due to the location and design
Coefficient of Variation (%)

12 requirements of the structure, the materials, the

10 mixing and placing equipment, and time constraints.
Emphasis is placed on determining optimum
8
water content for compactability at fixed cementitious
6
materials content. Selection of cementitious materials
RCC with Plasticizer-Retarder
4 content and water content is determined from design
2
RCC without Plasticizer-Retarder requirements, (Compressive, Tensile, Shear
Age
Strengths; Permeability, etc…), with consideration of
0
7 days 28 days 90 days 180 days
minimizing the cementitious materials content to
avoid thermal cracking. It could be said that the mix
Figure 09- dvantages in using Water reducer/Set design of a concrete is a process by which can be
Retarder admixtures, concerning the Mix obtained an adequate and economic combination of
Efficiency and Uniformity (coefficient of binder, aggregate, water and admixtures producing a
Variation) (From [14]) concrete which performs to the required specifications
The advantages of using admixtures that throughout its service life.
enhance workability and retard set for keeping It is the authors' opinion that design features
conventional mass concrete alive and preventing cold should take advantage of the economies of RCC
joints, particularly during hot weather, are well construction, looking for simplicity, quality, and
established. Water-reducing and set-retarding being economical. A mix design process must assure
admixtures have been used effectively in many the required property values; no segregation occurs by
projects mainly in China [13; 15 & 16] and Spain handling operations and performance requirements
[17]. are met using the proper materials. The diversity of
the structural designs, the environmental,
1.5. Water geographical and other conditions reflected, justifies
why several types of concrete exist which differ in
As RCC is a concrete, the usual requirement for water their composition and characteristics.
in CVC is adopted for RCC mixes. The requirement is RCC requires a mixture that will not subside
that it be free from excessive amounts of alkalis, excessively under the weight of a vibratory or other
acids, or organic matter that might inhibit proper roller but which will have an appropriate grading and
strength gain. paste volume to consolidate adequately under the
roller.
2 RCC MIX DESIGN The principal methods and ideas around
mixing processes have numerous aspects in common
2.1 General such as the need to adjust the concrete to the available
materials, required characteristics, and the placement
Roller Compacted Concrete (RCC) is a relative easy as well as to the economic conditions. RCC presents
and simple construction technique, but unfortunately two fundamental differences in composition with
up to now, has not yet a consolidated methodology for respect to their CVC counterparts:
design, mixes proportioning and laboratory tests. ƒ Firstly, RCC generally use an aggregate
Some authors or technical groups have shown combination that reduces the coarse fraction and
tendencies or advantages in adopting a procedure for increases the use of fine material, as previously
mix design. In a general point of view this could be mentioned, and;
summarized in specific tendency or experience that ƒ Secondly, RCC contains a reduced quantity of
could not be accepted as a general rule. There are a mixing water which is compatible with the transit of
number of methods that have been used for the design heavy duty earth-moving equipment over its surface
of the mixture proportions of an RCC. while it is still in a fresh state. This peculiarity of its
RCC mixture proportions should follow the placement means that RCC concrete must he studied
convention used in traditional concrete that is: and controlled when it is in a fresh state.
identifying the mass of each ingredient contained in
a compacted unit volume of the mixture based on 2.2 Routine
saturatedsurface- dry (SSD) aggregate condition.
A practical reason for using this standard As described, there are several methods that use the
convention is that most RCC mixing plants require 'concrete' approach for the design of the mixture
that mixture constituents be thus identified for input proportions of an RCC including that used for the
for the plant-control system. design of RCD mixtures. All the methods have
similarities and follow similar procedures although
there are minor differences. The routine [6] below mixture and on the grade of compaction that is
show the main conceptual points of the mentioned achieved. Given that, very diverse mixtures have been
approaches. The suggested procedure is as follows: employed, going from lean mixes to mixes with a
a) Optimize the gradation of the fine and coarse high-cementitious content; the values obtained in a
aggregates to produce minimum voids in each using series of properties have also varied very extensively.
additional mineral fines in the fine aggregate or The properties which depend on the nature of
available pozzolanic material if necessary. The mixes aggregates, such as their elastic or thermal
were proportioned in attempting the main objective to characteristics, are seen to be influenced by these
reach the maximum specific gravity. So the latter in a similar manner to that which occurs in CVC
aggregates can be combined to adjust as near as concretes.
possible from a curve type p= (d/Dmax)1/3 *100%;
b) Proportion the Portland cement, pozzolanic 3.2 Fresh RCC Properties
material (if any), water and admixture (if any) to
obtain the required property to obtain the proportions 3.2.1 Consistency Tests - Workability
of the paste. This can be modified to choose the
minimum cost mixture. For example if the pozzolanic The main purpose of consistency tests is to adjust and
material is cheap relatively to the cement and/or the determine the water content required to produce a mix
available fine material (silt, crushed powder filler or suitable for compaction by external rolling and to
other equivalent), a higher proportion of the obtain he desired strength properties. Workability of
cementitious content would be pozzolanic, while if it RCC mixtures is normally measured using a modified
is near the cost of the Portland cement, a lower VeBe apparatus[18] or the VC test in Japan[19]. The
proportion would be used; water content of the mix is determined by using a
c) Check that there is sufficient cementitious vibrating table to achieve the desired time for the
material (and a proportion of mineral fines, if used) to paste to start appearing on the surface of the RCC
provide the design permeability and durability; mixture.
d) Check that the fine aggregate/coarse aggregate The same specimen compacted and used for
ratio is close to the optimum; consistency can be useful for moisture-density tests.
e) Check that the heat of hydration is within the After the consistency test the container is weighed
expected limits; and the optimum water content (moisture) can be
f) Make any adjustments that are necessary determined as that one which produces a maximum
(laboratory and field) and re-check the design. dry density. Optimum water content (moisture)
content is thus determined for construction and should
3 TESTS AND PROPERTIES be in the mix at the time of compaction, not at the
time of mixing. It therefore may be necessary to
3.1 General introduce more water than optimum during mixing to
account for moisture loss due to handling,
RCC is a concrete, and so, the significant material evaporation, and early hydration of cement. Also,
characteristics and properties of RCC include: field adjustments may have to be made to produce a
ƒ Fresh RCC: consistency, unity weight, setting more compactable mix as determined by construction
time and uniformity; of a test section. RCC mixtures with the degree of
ƒ Hardened RCC: specific gravity, absorption, workability necessary for ease of compaction and
compressive strength, tensile strength, biaxial and production of uniform density from top to bottom of
triaxial shear strength, modulus of elasticity, Poisson's the lifts and for support of compaction equipment
ratio, tensile strain capacity, volume change (thermal, generally have a VeBe time of 20 to 30 seconds.
drying, and autogenous), thermal coefficient of
expansion, specific heat, creep, thermal conductivity, 3.2.2 Water Content- DMA- Brazilian Method
thermal stress coefficient, diffusivity, permeability,
and durability. Pacelli and al [20] developed a very simple and rapid
On a general point of view some doubts and method of test to determine the water content and unit
questions remain that comes from the inexperience of weight of RCC. Aiming to establish an alternative to
some technicians in the correlation and comparison of usual methods, a procedure for controlling the unit
the RCC data with those of CVC concrete, or in terms water of RCC and the unit weight of fresh concrete
of dams, with the CVC mass concrete. It means that, has been developed. Such method, known as " Water
besides the available data, there is no familiarity with Measurer Device - WMD (DMA in Portuguese),
the RCC Properties. Based on those doubts, this paper allows the prompt control of unit water during the
intends to discuss the RCC properties and quality in RCC production.
comparison with CVC properties, considering the This method has been conceived having as
large data obtained at job construction. physical principle, the density of materials
The in-situ properties of RCC depend on the compounding concrete. That is, as water is a material
quality of the materials used, or the proportions of the with lower density, the more water in a RCC mix, the
lower the density. The test consists in determining the
water volume displaced when a concrete sample of a 3.2.4 Setting Times
known weight is placed in a container (WMD) which
contains an also known water volume. The higher the The importance of identifying the setting times on the
water content in a RCC sample, the higher the water RCC which has just been compacted and, is still
volume displaced by the sample. For each RCC mix, fresh, is based on assuring an adequate adherence
the specific calibration curve must be made. This between layers. The horizontal joints between layers,
curve is achieved in laboratory by simulating the where the bond is required, becomes from the
conditions of water variation of the RCC mix impermeability and shear point of view, one of the
established to be used in situ. Such simulation is most vulnerable parts of the dam. The correct
carried out by batching at least five RCC mixes with identification of the setting times, for different
the same cement consumption per cubic meter. The atmospheric conditions, allows establishing the limits
unit water undergoes variation, the corresponding mix in time, for which a superficial treatment on the joint
is calculated again and the determinations to which should or should not be done, or the use of mortars of
the water volume displaced (ml) x unit water (kg/m3) bond, in order to guarantee the level of adherence of
x unit weight (kg/m3) will be correlated. An example design between layers. A recent methodology to
of the calibration curves is shown in the Figure 10. identify the setting times on RCC based on the
Theoretical Unit Water Measured Water Content Measured Specific Measured Specific
Weight (Kg/m3) WMD- Weight (Kg/m3) Nuclear
analysis of an ultrasound wave was introduced [21].
(Kg/m3) (Kg/m3) WMD-"DMA" "DMA" Densimeter The new methodology permits to identify the moment
120 120,67 2727 2710
130 141,51 2695 2721 when the initial setting begins on RCC, using the
140 134,16 2705 2705
150 144,58 2688 2672
ultrasonic energy parameter. The direct tension and/or
160 159,29 2665 2670 shear strength between layers and the time of setting
Figure 10- Measured Volume (WMD) * Unit can be correlated.
Water [6 & 20] Pressure
regulator

PUNDIT Oscilloscope

The apparatus used for these tests for measuring the Nitrogen

liquid displaced by the RCC is the same as the one Cylinder Concrete
specim en
Transducer

used before, at concrete batchers, for determination of Transducer

sand content. The time spent in carrying out each test Pneum atic piston Metallic support Pneum atic piston Lap-Top
computer
is around 8±2 minutes. The device is shown in Figure
(11) below.
Pressure
hoses

CONCRET O C OM PACT ADO C ON R ODILLO

(Presa Z anja Honda) (CCR TESTIGO)
[32ºC-70%H R]

16

14

12

10

6 Diamante ( Tipo II)=70 kg, w = 4.8%,

Grava 38 mm -19 mm = 544 kg
19 m m -12.5 m m = 249 kg,
12.5 mm -4.76 mm = 543 kg , Arena
4 triturada = 566 kg, Arena fina = 362 k

0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
Tiempo (horas)

ULTRASONIC ENERGY MIEL I (RCC Type I)

TEST M015 (00-01-20)
3000000
Figure 11- Device for determination of unit weight
and unit water of RCC 2500000

2000000

3.2.3 Unit Weight- Specific Weight-Specific Gravity- ULTRASONIC

ENERGY
(k jules) 1500000
Density
1000000

Although the density is mainly dependent upon the 500000

Relative Density of the aggregates to be used in the Initial Set

Iinitial

concrete, any entrapped air will lead to a loss of 0

0 10 20 30 40 50 60 70 80
AGE (Hours)
properties and also, if the air content is significant, to Reference CCR (w=4.5%) 0.7% Admixture CCR (w=4.5%) 1.0% Admixture
a greater volume of concrete having to be placed. The Figures 12a- Ultrasonic energy values evolution
aggregate volume in a concrete mix is about 80%, so and initial times of setting for different admixture
the concrete specific gravity depends mostly on the doses under controlled temperature and relative
aggregate specific gravity. RCC has a low air content humidity [21 & 22]
(generally 1% to 2%) and a low initial water content
so more solids occupy a unit volume.
 The ultrasonic energy concept becomes one least possible tendency to segregate. Limiting the
of these new advantages and permits to detect the maximum size of aggregate also helps reduce the
progressive growth of the solid phase (crystals) in a potential for segregation.
composite material. The energy parameter takes into
account the amplitude, frequency and intensity 3.3 Hardened RCC Properties
variations of the wave that goes through the material.
The material on its fresh stage, composed by a set of 3.3.1 Unit Weight- Specific Weight-Specific Gravity-
initial phase proportions, gaseous, liquid and solid, Density
changes these proportions when becomes rigid and
sets. The specific gravity of RCC is either the same or
DIRECT TENSILE STRENGTH OF THE RCC JOINTS
Miel I DAM
somewhat (2% to 4%) greater than that of CVC with
the same materials. The main reason for higher RCC
25
specific gravity is its lower water content and the
compaction ratio. Figure (13) shows some typical
20
RCC and CVC test-values, used at some projects [6].
15

RCC + 1% Plastiment RCC-M

w =4,5%
10

5 RCC Plain (Type I)

k =5,1%
w /

0
Initial set Initial set
0 RCC plain 5 10 15
RCC 1% Admixture 20 25 30 35
Time between layers (age of joint) [hours]

PERCEPTUAL LOSS OF ADHESION CAPACITY BETWEEN LAYES AT DIFFERENTS AGEs OF BASE LAYER
(EQUIVALENTS AGES) (RCC-Type I, Miel I)

100%
100%
100%

90% 86%
Figure 13- Specific gravity of concretes related
80%
77% with aggregate specific gravity [6]
70%
60%
60%
3.3.2 Strengths Compressive Strength
50% 52%

40%
34%
30%
Compressive strength is normally required because it
20%
26%
is relatively very easy to determine. Many other
10%
properties are directly related to the concrete's
Retarded RCC
0%

A
unconfined compressive strength at a certain age. A
B
C
D
RCC (Plain)
design age of 180 or 360 days is usually required for
RCC dams, and 28 days age for RCC pavements.
Time of Setting
These ages, for RCC dams, allow for some of the
30 long-term strength development of concretes
Miel I- 150kg/m3- 1,0% admixture
Porce III- 85kg/m3- 1,4% admixture containing pozzolanic material. RCC strength is
25 Porce III- 120kg/m3- 1,4% admixture dependent upon the quality and grading of the
Zanja Honda- 70kg/m3- 1,4% admixture
Zanja Honda- 70kg/m3- 2,0% admixture aggregates, the proportions of cement, pozzolanic
20 Pirris- 120kg/m3- 1,3% admixture material, and water, and the degree of compaction.
Rompepicos- 80kg/m3- 1,5% admixture
For most mixtures, the compressive strength of RCC
Hours

15 is a function of the water/cementitious ratio (w/(c+p)),

similar to traditional concrete.
10
To discuss the compressive strength in a
general way is very difficult because it depends of the
5
cementitious content (cement+pozzolanic material). A
normal way that can be used to correlate this
parameter is based on “mix efficiency = η ” that is a
0
Initial Setting Final Setting
factor [6]: η = [Compressive Strength (Kgf/cm2)] /
Figures 12b- Direct Tensile Strength at [Cementitious materials (cement + pozzolanic
Construction Joints and Time of Setting with and materials in Kg/m3)].
without Set Control Admixtures [21 & 22] “Mix Efficiency” at various ages for 60 RCC
and 18 CVC dams or studies is plotted in Figure (14)
3.2.5 Uniformity where data for these 18 CVC concretes could
compare RCC and CVC using the same constituents.
A major objective in the proportioning of RCC
mixtures is to produce a cohesive mixture with the
 Generally, “mix efficiency” at lager ages is aggregate quality, age, cement content, and strength.
higher for RCC than comparable CVC, meaning that Tensile strength of RCC can either be determined by
desired compressive strength of RCC can be obtained tests to measure direct tension or splitting (indirect)
using lower cementitious content, particularly tension. The splitting tension test is also known as the
Portland Cement, and higher pozzolanic material Brazilian Test. Like compressive strength, tensile
content. These types of mixes can develop more strength of RCC and CVC also depends on the
strength due to the best combination of cement and cementitious content and age. For CVC tensile
pozzolanic material. strength is considered to be 10% to 15% of
Roller Compacted Concrete (RCC) - Mix Efficiency
compressive strength. Data from 28 dams or testing
programs indicate that the average tensile strength of
3,00
RCC is also 10% to 15% of its compressive strength,
also.
2,50
The Direct Tensile Strength shows values
Mix Efficiency (kgf/cm2)/(kg/m3)

2,00
from 55% to 98% when related to Indirect Splitting
Tensile tests. TENSION RATIO (%) - SPLITTING TENSILE STRENGTH / COMPRESSIVE STRENGTH
DAM or CONCRETE

STUDY 5 10 15 20 25

1,50 MIDDLE FORK

CEDAR FALLS
GIBRALTAR
PAMO

RCC- Roller Compacted Concrete

LES OLLIVETES
SHIMAJIGAWA
1,00 MONKSVILLE
UPPER STILLWATER
WILLOW CREEK
ELK CREEK
URUGUA-i
ITAIPU
0,50 BUREAU- STUDIES
CAPANDA - CONSTRUCTION CONTROL
CAPANDA - DRILLED CORES - 6 YEARS
SERRA DA MESA
CESP-STUDIES
MIEL I- BASIC STUDIES
0,00 MIEL I - MIX DESIGN
MIEL I - CONSTRUCTION CONTROL

7 days 28 days 90 days 0,5 year 1 year > 5 years PORCE II

CANOAS - ASSARÉ
CANA BRAVA
Age JORDÃO
SALTO CAXIAS - CoONSTRUCTION CONTROL
SALTO CAXIAS - CORES
ERIZANA - MIX DESIGN
ERIZANA - CONSTRUCTION CONTROL

Conventional Vibated Concrete (CVC) - M ix Efficiency MOLONGLO - MIX DESIGN

SANTA EUGENIA - MIX DESIGN
SANTA EUGENIA - CONSTRUCTION CONTROL
LAKE ROBERTSON
3,00 AUBURN- STUDIES
ITAIPU

CVC
SOBRADINHO
ITAPARICA
AGUA VERMELHA
2,50
Mix Efficiency (kgf/cm2)/(kg/m3)

TENDENCY RCC

2,00 Figure 15- Ratio Indirect Tensile and Compressive

Strength
1,50

1,00

0,50

0,00
7 days 28 days 90 days 0,5 year 1 year > 5 years
Age

Roller Compacted Concrete (RCC) - Mix Efficiency

3,00

2,50
Mix Efficiency (kgf/cm2)/(kg/m3)

2,00 Figure 16- Direct Tensile Test

1,50
3.3.2.3- Shear
1,00
The shear strength of RCC is dependent upon its
0,50 tensile bond properties (cohesion) and angle of
internal friction. Minimum strength occurs at
0,00
construction joints and along the interface between
7 days 28 days 90 days 0,5 year 1 year > 5 years
lifts of RCC. Construction of a concrete dam using
Age
RCC structure with lift lines every 0.3m to 1.0 m
Figure 14- Mix Efficiency- RCC and CVC vertically. The shear strength at the compacted lift
concretes lines is more important to the designer than the shear
strength of the parent material. Ideally, mass concrete
3.3.2.2- Tensile Strength in a dam body should be monolithic. A construction
joint, whether planned or unexpected, if untreated,
The ratio of tensile strength to compressive strength can become a discontinuity or a plane of weakness in
for RCC mixtures have typically varied depending on the concrete mass. Horizontal joints are inevitable in
CVC and RCC dams because of the layered method the base layer, between 50 to 60% of the initial value
of construction. obtained when the joint is fabricated just after the
The performance of an RCC dam will almost base layer was compacted. The direct tensile strength
entirely be dictated by the performance of the on the horizontal joint decreases progressively with
horizontal joints between the layers. In addition the the time of exposure of the base layer, even before the
joint surfaces must be scrupulously clean. However, if initial setting takes place. The definition of the limit
any of these factors are not present, the performance of hot joint as the instant of initial setting, takes into
of the joint may be less satisfactory. Therefore, it is account a drop in the capacity of bond to 77% - 86%
necessary to prepare, clean and treat each construction to the direct tensile strength, obtained in joints
joint before placing a new concrete lift, in such a fabricated immediately after base layer was
manner that the joint would have adequate bond and compacted. An investigation[23] indicated the
shear strength to assure integral elastic behavior of the following regarding the performance of joints
entire concrete structure. Bedding mixes used on the between successive layers of RCC subjected to
surface of the layer will improve the shear and tensile different types of treatment:
strength of the joint for a given set of conditions. ƒ If the time interval between layers exceeds 8
hours, without any treatment, there would be a 25%
reduction in the effective bond strength of the joint
ƒ The use of a bedding-mix would improve the
strength of the joint more than 34% regardless of the
interval time between lifts.

Clean-up of the RCC joints with low-pressure

air-water jets showed only a small improvement in
joint strength (16% comparing conditions V and II in
Figure (18). The total shear strength can be
determined using Coulomb's equation:

τ = C + σ *tan(Φ)
where
τ = unit shear stress;
C = unit cohesion;
σ = unit normal stress, and;
Figure 17a- Direct tensile strength on the RCC Φ = the angle of internal friction
joints with mortar compared with parent RCC

Figure 18- Serra da Mesa Cofferdam Tensile

Stength [6 &23]

The cohesion C is also called the bond stress, while

σ*tang(Φ) defines the sliding friction resistance. A
direct shear test is the usual method for obtaining
cohesion and angle of friction data using various
normal loads. The break bond shear strength may also
Figure 17b- Splitting tensile strength on the RCC be called the peak strength, and the “sliding friction”
joints with mortar compared with parent RCC values denote the residual shear strengths.
From references [21 & 22] can be seen These tests are done to get the Mohr-
(Figure 17) that the direct tensile strength on the Coulomb Envelope, and so the cohesion C (shear
horizontal joints decreases after the initial setting of
strength) a friction angle Φ . The laboratory tests on rock (meta-sandstone) foundation contact at Capanda
monolithic- RCCspecimens could be done in: dam[6].
ƒ Triaxial Chamber similar in aspect, but greater in
dimensions than that used for soil-mechanics, or
rockmechanics. In this way it is possible to change the
confining pressure and determine the axial
compressive value, as shown in Figure 19; or

ƒ Direct Biaxial Shear test, is normally used in

rock-mechanics, when a normal load is applied and
the shear (with a little angle of the plane due the
methodology) load measured (see Figures (20); or
ƒ Direct Unconfined Shear test, based on the
CRDC- 90, Corps of Engineers Method of Test,
where the shear load is applied in a single and non-
confined plane.
Figure 22- Biaxial shear test for concrete cores

Figure 19- Triaxial chamber used for concrete

tests

Figure 23- Biaxial shear test in situ at Salto Caxias

Dam- Brazil

It is very important to show this, because it is

possible to see that:
ƒ The shear (cohesion and friction) values at
construction- joint, (normally well treated and with
"Bedding- mix"), are greater than the one obtained for
the rock-foundation contact;
ƒ The shear values at construction joint, without
“Bedding-mix", are in the same range as the one
Figure 20- Biaxial shear test apparatus obtained for the rock-foundation contact.
ƒ Results of direct, biaxial and triaxial tests
The specimens from the RCC-Construction Joints performed on cores obtained from test fills and
could be tested in: completed dams, and “in situ” tests, indicate that the
shear strength components C and Φ are comparable
ƒ Direct Biaxial Shear test - “in laboratory”- as to that of CVC made from similar aggregates. While
shown in Figures 20 and 21, on specimens drilled cohesion is dependent on the cementitious content,
core from a trench, or from a large scale test-fill, or the angle of friction is affected by the quality and
from a large specimen (for instance cast a 45x90cm gradation of the aggregates.
specimen with a construction-joint in the central part,
and after drilling a core throughout the construction- 3.3.3 Modulus of Elasticity
joint); or
ƒ Direct Biaxial Shear test - "in situ"- in a large The modulus of elasticity “E”, also known as Young's
scale test-fill, as done at Urugua-I, Capanda and Salto modulus, is the ratio of the normal stress to its
Caxias Dam dams and as shown in Figures 22. corresponding strain for compressive or tensile
stresses below the proportional elastic limit of the
Typical values of shear strength parameters for some material. Principal factors that can affect the modulus
RCC and CVC dams and studies are shown in Figures of elasticity of RCC and CVC values are:
23. Figures 24 show values from Figure 23, and ƒ Age of tests- The modulus increase with age up to
Figure 25 compares values from shear tests from the
maximum value that correspond to the maximum that modulus values for a given strength concrete.
could be reached by the mortar or the aggregate Similarly, a lower elastic modulus results from the
(which is lesser); use of a sandstone or similar aggregate. RCC
ƒ Aggregate type (and its modulus)- At large ages mixtures made with conventional concrete aggregate
the concrete modulus could be similar to the one of and a relatively high content of cement or cement plus
the aggregate if a rich mortar was used; pozzolanic can develop moduli similar to those
ƒ Water cement ratio (or the “paste” obtained in conventional concrete. In most mass uses,
proportioning)- As concluded from the above a low modulus is desired to decrease the crack
mentioned, rich mix: high values, and poor mix: low potential. Lean RCC mixtures using natural or
values. manufactured fines as filler have resulted in very low
Aggregate such as quartzite and argillite can moduli.
generally produce higher than average elastic

Figures 24a. .- Typical shear values (Coehesion and Friction) from tests and conditions on RCC and CVC

Figures 24a. .- Typical shear values (Coehesion and Friction) from tests at RCC Construction Joints
 to the larger content of mortar in RCC mixes than that
of CVC mixes the coefficient of creep “f(k)“ of RCC is
larger than that obtained for CVC made of similar
aggregates.

Figure 27- Poisson’s Ratio

When concrete is subjected to a load, the deformation

caused can be divided into an immediate deformation
such as an elastic strain (related to the Modulus of
Figures 25- Shear test results (Cohesion Friction)- Elasticity) and a time-dependent (related to the period
Rock Foundation Contact- Metasandstone and of time under load) compressive deformation called
RCC creep. Creep begins immediately and continues at a
decreasing rate for as long as the load remains on the
concrete. The total creep is mainly affected by the
aggregate modulus of elasticity and by the filler
material that was used in the concrete proportioning
mix. Figure (28) show some values[6] in comparison
with creep values of CVC

Figure 26- Modulus of Elasticity – CVC and RCC

Results

3.3.4 Poisson’s Ratio

Poisson's ratio value is the ratio of transverse (lateral)

strain to the corresponding axial (longitudinal) strain
resulting from uniformly distributed axial stress
below the proportional limit of the material. It appears
that values for RCC are similar to values reported for
CVC mixtures. A range from about 0.17 to 0.22 has
occurred as shown in Figure 27.

3.3.5 Creep Figure 28 - Creep values from RCC and CVC

It can be noted that from the creep equation ε={[1/E] concretes
+[f(k)]*[log (t +1)]}, normally used, the ratio 1/E of
Generally, aggregates with a low modulus of
RCC mixes - at early ages- is grater than that of CVC
elasticity will produce concrete with high creep. For
mixes, due to the higher mortar content of RCC. Due
most mass concrete applications, the ability to relieve produces an adiabatic temperature rise in a manner
sustained stress is desirable to relieve thermal stress. similar to CVC concrete.
Higher strength mixtures generally have a more rigid
cementing matrix and lower creep, which results in 3.3.8 Thermal Properties
increased thermal stress. Lean mixtures and those
made with inert fillers of natural or manufactured The thermal properties- Diffusivity, Specific Heat,
fines have higher than normal creep. Conductivity and Coefficient of Thermal Expansion
[6] (see Figure 30) - depend mostly on the aggregates
3.3.6 Tensile Strain Capacity thermal properties and the degree of saturation in the
hardened RCC. The RCC properties that may be
The strain capacity is considered as the ultimate needed in a thermal analysis include specific heat,
deformation under tension before the rupture. Strain is diffusivity, conductivity, and coefficient of thermal
induced in concrete when a change in its volume is expansion, together with tensile-strain capacity.
restrained. When the volume change results in tensile
strains that exceed the capability of the material to 3.3.9 Volume change
absorb the strain, a crack occurs. The major factors
affecting strain capacity are the rate of loading, type In any massive concrete structure, the understanding
of aggregate, shape characteristics (angular as of and the design for volume changes is necessary to
produced by crushing versus natural round), and the minimize uncontrolled cracking. The reduction of
cement content. Generally, the hard brittle aggregates volume due to thermal, or drying shrinkage, or
such as argillite and quartzite produce lower strain autogenous volume is of concern in the design of
capacity. Crushing or addition of crushed material RCC dams.
usually improves strain capacity by increasing tensile
strength. 3.3.9.1- Drying shrinkage

3.3.7 Adiabatic Temperature Rise Volume change from drying shrinkage in RCC is
minimized by virtue of the reduced water content.
The adiabatic temperature rise due to the heat of Increases in moisture cause concrete to expand and
hydration, for both types of concretes is obtained by decreases in moisture cause it to shrink. In the cement
the same way, using a large dimension calorimeter. hydration process, water combines with the cement so
The adiabatic temperature rise for both types of the basic process is one of moisture loss or shrinkage.
concrete is essentially proportional to the In any concrete mix, it is only the paste that shrinks.
cementitious content of the mix. So for a constant cemetitious content, the drying
shrinkage rate depends primarily on the amount of
water in the mix. Because RCC requires less water on
the other hand, if marginal aggregates that have a high
water demand and resulting drying shrinkage are used
to produce RCC, it will have a corresponding volume
reduction with moisture loss.

3.3.9.2- Autogenous Volume Change

Autogenous volume change is primarily a function of

the aggregate and its long-term stability with the
cement being used. Each job should be evaluated after
a review of a petrographic analysis of the aggregate,
Figure 29- Adiabatic temperature rise in terms of review of historical information, and tests, if
“coefficient of temperature rise values” from RCC appropriate. Lower cement factor mixtures tend to be
and CVC concretes more stable. Natural fines used in RCC may also
affect volume change and should be taken into
The values can be shown in two different account. As with conventional concrete, the change
manners. One in terms of temperature degrees, in an can generally be expected to be minor, but it should
absolute value range; Other manner that gives a be considered.
simples way to general comparisons is a ratio between
temperature degrees of adiabatic rise, per 3.3.10 Permeability
cementitious (cement plus pozzolanic material)
content, that is called “coefficient of temperature The coefficient of permeability is obtained by tests
rise” and is shown in Figure (29) [6]. The most using an apparatus like the one shown in Figure (31).
important item is to get the maximum “mix The coefficient of permeability values from RCC and
efficiency” (as described previously), and the CVC mixes are shown in Figure (32) [6].
minimum “coefficient of temperature rise”. RCC
 COEFFICIENT OF THERMAL EXPANSION
DAM MIX CONCRETE AGGREGATE CEMENTITIOUS COEFFICIENT OF
CONTENT THERMAL EXPANSION
Kg/m3
10 6/oC
URUGUA-i PM - 60 RCC BASALT 60 7.41
URUGUA-i PM - 90 RCC BASALT 90 8.33
ITAIPU 76 - D - 04 CVC BASALT 189 8.0
ITAIPU 76 - D -04 CVC BASALT 162 7.71
MIEL I TEST RCC QUARTZITE- GNEISS 75 7,5
SPECIFIC HEAT
DAM MIX CONCRETE AGGREGATE CEMENTITIOUS SPECIFIC
CONTENT HEAT
Kg/m3 cal / g.oC
URUGUA-i PM - 60 RCC BASALT 60 0.238
URUGUA-i PM - 90 RCC BASALT 90 0.233
ITAIPU 76 - D - 04 CVC BASALT 189 0.243
ITAIPU 76 - D -04 CVC BASALT 162 0.242
LAKE ROBERTSON RCC-1 RCC GRANITE-GNEISS 170 0.225
LAKE ROBERTSON FC- 3 CVC GRANITE-GNEISS 320 0.225
CAPANDA RC - 60 RCC META-SANDSTONE 60 0.221
CAPANDA 152 - 150 - B CVC META-SANDSTONE 150 0.228
CAPANDA 152 - 100 - A CVC META-SANDSTONE 100 0.223
70 0,225
MIEL I RCC QUARTZITE- GNEISS 85 0,235
130 0,245
CANOAS RCC QUARTZITE 80 0,25
THERMAL DIFFUSIVITY AND THERMAL CONDUCTIVITY
CEMENTITIOUS THERMAL THERMAL
DAM MIX CONCRETE AGGREGATE CONTENT CONDUCTIVITY DIFFUSIVITY
-3 O -3 2
Kg/m3 10 (cal /cm.s. C) 10 (m / day)
URUGUA-i PM - 60 RCC BASALT 60 4.76 0.066
URUGUA-i PM - 90 RCC BASALT 90 4.22 0.060
ITAIPU 76 - D - 04 CVC BASALT 189 4.41 0.062
ITAIPU 76 - D -04 CVC BASALT 162 4.60 0.063
LAKE ROBERTSON RCC-1 RCC GRANITE-GNEISS 170 4.05 0.086
LAKE ROBERTSON FC- 3 CVC GRANITE-GNEISS 320 4.05 0.086
CAPANDA RC - 60 RCC META-SANDSTONE 60 6.0 0.093
CAPANDA 152 - 150 - B CVC META-SANDSTONE 150 7.0 0.111
CAPANDA 152 - 100 - A CVC META-SANDSTONE 100 7.4 0.116
Miel RCC QUARTZITE - GNEISS 85 6,8 0,110
Canoas RCC QUARTZITE 80 8,9 0,110

Figure 30- Thermal properties values from RCC and CVC concretes

The permeability of a concrete mass is largely

dependent upon the entrapped air and porosity of the
hydrated cement matrix and therefore is almost totally
controlled by mixture proportioning, quality control,
and degree of compaction. When there is sufficient
fines, controlled fine-particle distribution to minimize
the air void system, and full compaction, RCC will be
relatively impervious. In general, an un-jointed mass
of RCC made from clean conventional aggregates
with sufficient paste or very lean mixtures with
controlled aggregate grading containing sufficient
fines will have permeability values similar to CVC
concrete.
The property that has caused greatest concern
to designers of RCC dam is the in-situ permeability of
RCC. Although the permeability of the parent (un-
jointed) material may be low, it is the joints between
the layers that are the main cause of the difficulty. Figure- 31 -Permeability apparatus test, at
Nevertheless it has been shown that it is possible to FURNAS laboratory- Brazil
obtain an effectively monolithic and impermeable
structure when RCC is placed in layers. The total The coefficient of permeability of the tested
seepage through an RCC dam is the sum of the water construction joints ranged from 1*10-9 to 1*10-11m/s,
passing through the material itself (Permeability) plus which is comparable to that of the concrete. As shown
that through any cracks or joints in the structure. in Figure 32 the Coefficient of Permeabilty of RCC
The improved RCC mixes which have about ranges from 10-6m/s to 10-12m/s with cementitious
the same coefficient of permeability as CVC are more content from 60Kg/m3-250kg/m3, as compared to 10-9
suited for construction of high gravity or arch/gravity to 10-12m/s for CVC with similar cementitious
dams. The use of higher percentage of non-cement content.
fines, or filler, or pozzolanic material, in a RCC mix,
contributes to its low permeability, without increasing
the potential for thermal cracking.
 Pavements at heavy-duty facilities such as
log-storage yards and coal-storage areas have shown
no appreciable wear from traffic and industrial
abrasion under severe conditions.

3.3.11.2- Freeze-thaw resistance

Experience has shown that RCC made with a

substantial amount of clayey fines will check and
crack when subjected to alternating wet-dry cycles.
RCC made with non-plastic fines or with no fines has
shown no deterioration from wetting and drying.
Because proper air entrainment in RCC is generally
not attainable with admixtures, freeze-thaw resistance
must come from its strength and impermeability.
If RCC mixes are designed for durability
using freezethaw weight loss tests and criteria as
developed for soilcement, acceptable freeze-thaw
durability can be expected. The amount of cement to
produce a sufficiently durable RCC mix may be
greater than that required to achieve other properties
such as compressive strength. Little or no pozzolan
replacement for cement is advised where horizontal
RCC surfaces will be exposed to early freeze-thaw
cycles while wet because high early strength is
Figure 32- Coefficient of Permeability values from required under these conditions.
RCC and CVC concrete mixes, with and without
fines and pozolanic materials [6] 4 INSPECTION AND QUALITY CONTROL
REQUIREMENTS AND PRACTICES
3.3.11 Durability
4.1 General Aspects
The RCC mixture should provide the required degree
of durability based on the exposure conditions, the Who is it that does not want assurance that the
materials used and the expected level of performance. concrete job in which he is involved will achieve the
RCC should be free of damaging effects of alkali- quality necessary to give good performance and great
aggregate reactivity by proper evaluation and appearance throughout its intended life? Probably no
selection of materials. Durability of RCC is especially one.
important if the material is exposed to weather or
severe hydraulic forces. Its durability has been ƒ The designer wants it; his reputation and
documented by both laboratory tests and case studies professional satisfaction depend on it.
in the field. ƒ The builder wants it for much the same reason,
but sometimes there are adverse influences such as
3.3.11.1- Erosion or Abrasion Resistance time and money problems.
ƒ The owner wants it; his money is in the project
The erosion resistance of RCC is proportional to its and he has to live with what he gets. Any
compressive strength and the abrasion resistance of governmental agency responsible for public welfare
the aggregate used in the mix. RCC has shown good and caring of its reputation wants it.
resistance to erosion and abrasion both in the ƒ Why then, if all responsible parties want quality,
laboratory and in the field. it is not automatically achieved?
The erosion-resistance properties of RCC ƒ Why is it necessary to consider what it takes to
have been demonstrated on many projects. The most get and assure quality?
notable are the Salto Caxias dam, the spillway ƒ Perhaps the answer lies on the inadvertencies, not
rehabilitation at Tarbela Dam, the spillway for the ƒ uncommon in construction activities.
North Fork of the Toutle River debris retention dam, ƒ Perhaps it lies in the loss of pride in craft.
and the Kerrville ponding dam. Salto Caxias RCC ƒ Perhaps it is inherent in human nature and culture.
Dam, during the period from August/1997 to ƒ More than many centuries ago in 79 AD,
November/1997, was overtopped five times with a Frontinius, the operations and maintenance
flow of 5,500m3/s (13,100m3/s in total with superintendent for the famous Roman aqueduct,
7,600m3/s throughout the sluiceways) noted, possibly with a touch of exasperation, after
describing the procedure necessary for making secure
repairs, that these were things "which all the workmen firm requirement of compliance with non-material,
know, but few observe." performance aspects of the specifications.
ƒ Perhaps, because people are no different today, A good specification is that which only
we need to do something special to insure quality in requires things that need to be done to make the
concrete construction. concrete suitable for its purpose. It contains no
Quality control is no different on concrete requirements that can be ignored or slighted and omits
construction work. Basically this is inspection and the no requirements that must be met. With a “good
related testing of materials and concrete. It is specification” neither the contractor nor the inspector
however, more than making a few slumps (CVC has any doubt as to what must be done. With such a
construction) or consistency tests (RCC construction) specification, any part of the work that is not in
and cylinders for strength tests. The full scope of accordance with the requirements must be changed so
duties and responsibilities of the inspection and that it does comply. The question of whether it is
testing staff are only effective if it includes everyone "good enough," even though not as good as required
interacting with them. by the contract will not arise.
The few jobs that do not satisfactorily serve
4.2 The Need for Inspection their purposes do so, in nearly every case, for several
reasons rather than a single reason. Some of these
The purpose of inspection is to assure that the reasons are:
requirements and intentions of the contract documents (a) Failure of the owner to understand what he
are faithfully accomplished. The term inspection as needed;
used in concrete construction includes not only visual (b) Failure of the engineer to understand the owner's
observation and field measurements, but also needs and to translate these needs into proper quality
laboratory testing and the assembly and evaluation of levels of relevant properties and into correct
test data. specification requirements for the work;
One important responsibility for the concrete (c) Failure of all concerned with establishment of
inspector is the quality of the materials used in the specifications to include only what was needed and
concrete. Often low quality raw materials, particularly exclude what was not needed;
aggregate materials, can be used to produce concrete (d) Failure to require uniform compliance by the
of satisfactory quality if they are suitably processed or contractor with all requirements of the contract;
prepared. However, the final materials entering the (e) Failure by the contractor to comply with all
concrete mixture must be of specified quality. It is requirements of the contract.
difficult and usually impossible to produce specified Inspection is not an end in itself. Inspection
concrete from nonconforming materials. On the other and testing by themselves do not add quality to the
hand, a principal ingredient needed for specified product or process being inspected. Inspection and
concrete construction is good quality workmanship in testing only confirm whether the product or process
all operations and processes. It has been said that meets the criteria established. The information
most good concrete is made from tested and certified derived from the inspection and testing process,
cement; sound, durable, well graded, and properly however, when properly evaluated and with
tested aggregates; suitable admixtures; and clean, conclusions and decisions implemented, will result in
pure water-and most nonconforming concrete is made improvement of the quality of the product or process.
from the same good materials. It must also be recognized that quality is achieved
only by implementation of an adequate quality
4.3 Specification Inclusions program from planning through design and
construction, to acceptance by the owner.
The task of inspection will be easier and thus more Quality during the construction phase is
effective, and job results will be better, if the achieved almost entirely by the contractor or
specifications include as many requirements as producer's quality control program. This quality
possible to insure accomplishment of the intended control program involves everyone from management
result with relatively little inspection. This broader to field supervisors to the workmen themselves.
concept for quality construction with CVC or RCC Quality control must have the strong active support of
will also include any pre-testing of materials, mixes, top management, and the active concern and
and concrete properties needed to insure that they will participation of everyone involved in the construction
be suitable for the work. process.
During construction they will be regularly
tested for compliance and performance, and results 4.4 Statistical Concepts in Quality Control
will be recorded. Specifications will state that
sampling, testing, and evaluation of results for The science of statistics is a versatile tool. Its use
acceptance will be based on statistics patterns, not on permits decisions to be made with an established
a single test. Concessions made under it, though degree of confidence. Contract documents can be
probably reasonable in some aspects, tend to weaken written using statistical concepts to express quality
requirements as target values for contractors, and to that the required quality is achieved. It is obvious that
express compliance requirements as plus or minus the design of projects where little quality control is
tolerances. Tolerances for the target value, prescribed anticipated should be more conservative than the
by design needs, can be based on statistical analyses design of a project where a very effective quality
of the variations in materials, processes, sampling, control program is anticipated. For most projects the
and testing existing in traditional construction quality control requirements are specified in the
practices. Tolerances derived in this manner can be contract documents, or by separate agreement with a
both realistic and enforceable. They take into account quality control organization. The preparation of those
all the normal causes of variation and allow for the documents should be coordinated with project
expected distribution of test results around the designers so that the design requirements are suitable.
average. Provisions can be made both for control to While quality control is usually considered to
the stated level and for control of the variation from be an activity performed during RCC placement, it is
this level. also important that quality control issues be
considered during design, planning, and the initial
4.5 Records phases of construction of an RCC project.
A viable Quality Control System should
Quality control in construction is not a reality without consider the numerous construction operations basic
records that give that assurance. These records must not only to RCC but also to the CVC, and how they
be systematically and presentably kept. They must be are performed. Preparation and advance planning are
accurate, consistent, and believable. But they need not the key to success and quality construction. Pre-
be excessive in coverage and should not be redundant. construction meetings, pre-construction testing, and
pre-construction evaluations such as test sections are
4.6 Quality Plan critical parts of the quality program. Once the
concrete (RCC and CVC) placement is under way, the
An overall (Total?) Quality Plan or System for a more traditional concepts of quality control become
construction can describe in general terms the Quality evident, but advance planning and preparation
Control System used for the a project with emphasis continue to be important.
on: The control can be based on the following
ƒ The quality objectives to be attained; main items:
ƒ The specific allocation of responsibilities and ƒ A qualified team;
authority during the different phases of the project; ƒ Adequate and modern technology;
ƒ The specific procedures, methods and work ƒ Adequate equipment and facilities;
instructions to be applied; ƒ Elimination of mistakes and defects;
ƒ Suitable testing, inspection and examination at ƒ Monitoring of the process;
appropriate stages; ƒ Standardizing
ƒ A method for changes and modifications in a
quality plan as the project proceeds; The objective of Quality Control is to ensure that the
ƒ Other measures necessary to meet objectives. characteristics of received or produced materials and
equipment are preserved. Adequate care and methods
The main objective of each quality plan is to give the will be employed in the handling of materials and
project manager the overall tool assuring that the equipment. Whenever necessary, specific
work in the different phases is executed in a arrangements will be made for the handling of
controlled manner. Personnel performing activities sensitive equipment. All data and information relative
affecting quality must be appropriately trained and to the Quality Control System must be collected in a
records will be kept of executed training. Records of standardized routine and accurate manner, to give
training and a list of persons authorized to perform evidence of the required quality for materials and
certain tasks must be kept and maintained by the equipment. Records will include the following
respective members of the team. features:
Procedures need to be established, maintained
and documented in order to perform, verify and report ƒ Quality Control as used herein refers to all
that the service meets the specified requirements. The functions involved in obtaining quality materials to
reliability, availability and maintainability of the provide satisfactory services;
operation need to be monitored and reported. ƒ Periodical reports based on statistical analyses
The Quality Control System tries to increase must be made for all items in the project;
the quality and productivity of the works and reduce ƒ Before concrete production starts, all materials
costs. It must be designed to prevent and eliminate or will be analyzed according to their properties and
reduce mistakes during the construction works, and only those in conformity with the standards will be
provide repairs, if and when mistakes occur. The chosen.
design of a structure should be accomplished
considering what measures will be required to insure
RCC placing rates can be extremely high when site among key personnel of the contractor,
compared to conventional concrete. Placing rates in inspection/quality control organization, and field
excess of 400m3/hr has been achieved on some large design personnel has been responsible for avoiding
projects. Small structures have been constructed in work stoppages and unnecessary removal of
only a few days or weeks. With such rapid placement questionable material.
rates or short-term construction periods, problems Based on what was described above, it can be
must be evaluated and solutions implemented in a suggeste that before the works start a “Quality
short period of time. Any problem that delays RCC Control Plan” and a “Manual for Quality Control”
placing essentially delays the whole production. Good should be adopted. This "Manual" proposes measures
communication among the owner, engineer, which include the following basic points:
inspection personnel, and contractor personnel is ƒ Be aware of possible problems;
essential. The most common placement delays are ƒ Anticipate possible corrections;
usually due to problems caused by: ƒ Guarantee quality;
ƒ Seek modifications and improvements;
a) Insufficient materials ƒ Be objective, dynamic and compatible with the
b) Foundation preparation and cleanup pace of construction;
c) Joint cleanup ƒ Controls must include materials and concretes
d) Equipment breakdown (RCC and CVC);
e) Weather condition (hot or cold ; wet or dry; rain)
For an overall view of the scheme that can be
After the selection of the materials (cement, adopted Figure 33 shows a flow chart of actions with
pozzolanic materials, aggregates, water and the following points:
admixtures) available for use according to the Action 1 - Pre-qualification and knowledge – This
standards and specifications, concrete mixes must be corresponds to the stage of initial studies, knowledge
designed by the laboratory, in compliance with an and selection of materials and suppliers;
adopted “Recommended Practice” or Standard. Action 2 – Information on handling;
Materials inspected for acceptance before being Action 3 - Control of arrival (delivered) of material -
shipped to the job site can have their status checked This action seeks to guarantee quality and uniformity
for damage during shipment and storage. of the material and products, based on pre-
It must be assured that all personnel are qualification data. These tests are proven by
correctly selected, trained, qualified and motivated so certificates, and can be performed by each supplier;
that the results anticipated by the company will be Action 4 - Control during production - This action is
attained and even surpassed. A key element in to evaluate the points or procedures that could be
resolving potential problems in advance is to assure vulnerable during production;
that all participants understand the project Action 5 - Control of application - This point consists
requirements, and that necessary procedures are of disciplinary actions during production.
clearly understood. Basic issues that must be Action 6 - Inspection during execution - This action
considered in advance are: will have the function of evaluating the best
Staffing- Sufficient laboratory and inspection procedures for executing the works;
personnel should be trained and available for the Action 7 - Structure commissioning – This item will
anticipated production operations. Shift overlaps and have the function of formal commissioning of each
transitions require advance planning. All staff stage of structures or services.
members must know what is acceptable and
unacceptable, and they must consistently apply In addition to inspection activities, a comprehensive
acceptability criteria. Whenever necessary, the work RCC quality control program should monitor the
will keep proof on file showing that executive and aggregate properties, RCC mixture proportions, fresh
quality personnel are qualified and/or certified by an concrete properties, hardened concrete properties, and
agency of recognized competence. inplace compaction. An example of possible tests and
Facilities and equipment- Appropriate test frequencies are given in Figure 34, which was
testing facilities and equipment for the size and successfully adopted during Capanda RCC Dam
volume of tests that may become necessary must be construction in Angola and others RCC jobs where
available in advance of RCC related work. the author have cooperated [6]. The frequency and
Technicians should be trained in the proper use of the extent of testing should be adjusted according to the
equipment and in the proper implementation of the size of the project, the sensitivity of the design to
test methods. variations in quality, and the rate of RCC production.
Communications- The project staff should Quality control of the material and concrete used for
meet with the contractor to review and discuss the Capanda project, was the Contractor’s
requirements and procedures for RCC material responsibility. To perform these activities, a “Quality
production, placement, testing, inspection, and job Control Plan” was devised, in order to comply with
site safety. Adequate radio communication at the job design and specifications requirements. Logistic
conditions for construction of the development were conditions. This, in turn, affects water requirements,
also considered such as, purchase of basic materials, compaction characteristics during construction, and
distance from site to production centers, quantity and the quality of the concrete. Normally, construction
quality of labor available, schedules, and assurance of activities continue throughout a variety of warm, cold,
quality parameters compatible with the magnitude of wet or dry ambient conditions. Quality Control
the works. Figure 34 shows, in schematic form, the System personnel should assure that continuous
Quality Control Plan established. adjustments in moisture and, if appropriate, other
The “goal” of quality control is to identify mixture proportions are made to adapt to these
problems before they occur or sufficiently early in the conditions. All personnel must communicate between
process so they can be corrected. Monitoring and shifts about these adjustments in order to achieve
reacting to the trend in performance is preferable to continuity of the product.
reacting to specific test results. The trend, identified Even more than in CVC, the use of
by a series of tests, is more important than data compressive strengths test on concrete specimens as a
provided by a single test. By continuously tracking method of control in RCC construction has a major
trends it is possible to identify detrimental changes in disadvantage in the time required in obtaining results.
material performance and initiate corrective actions. Because of the rapid rate of placement in RCC
Further, it is possible to modify the frequency of construction, and the fact that layers of material can
testing based on trend performance. For example, it is be covered with new lifts within hours, test cylinders
common to specify a high testing frequency during serve as record data for quality and are not an
the beginning of aggregate production and to later effective method of day-to-day quality control.
reduce the testing frequency as production stabilizes Emphasis on thorough control of materials
and the trend in grading stabilizes. (gradation, cementitious content, and moisture
Tests must be performed rapidly. The rapid content) and conditions during placement is essential
placing rates and typical 20 or 24 hour per day to proper RCC. If the aggregates are as specified with
construction timetables require careful attention and regard to source and quality, the cementitious
interaction between Quality Control testing, materials are pre-tested from pre-qualified sources,
inspection personnel, and production personnel. If the technique and timing of mixing, spreading, and
Quality Control System activities cause significant compacting are within the designated guidelines, and
delays to any stage of RCC production such as an appropriate method of curing is followed, the end
mixing, placing, compacting, or foundation cleanup, product will be acceptable.
all construction may be affected and possibly stopped.
Fresh RCC properties may vary with daily,
weekly, or monthly fluctuations in ambient weather

ST UD IES ; R ES EA R C H ; P R E - Q UA LIF YIN G ; ST A T IS T IC A L D A T A

A

C EM ENT P O Z Z OLA N IC A D M IXT UR ES WA T E R R OC K F OR SIN T E T IC S R EIN F O R C EM EN T IN S ER T S F OR M WO R K IN T R UM E N T S

M A T E R IA L A G G R EG A T E S E P OX IES A N D SP LIC ES
O R D ER T O B E D E LIVE R ED ; R EC E P T IO N
B

ST OC K ST O C K ST OC K ST OC K P R O D UC T ION ST O C K H A N D LIN G P R OD UC T IO N P R O D UC T IO N C A LIB R A T ION

AND ST O C K A N D ST O C K A N D ST OC K A N D ST OC K
P R O P O R T IO N IN G M IX; C A LIB R A T IO N ; IN SP EC T ION
C

C O N C R E T E - C VC A N D / O R R C C P R EP A R A T IO N P R E P A R A T IO N P R E P A R A T IO N P R EP A R A T IO N P R EP A R A T IO N
B A T C H IN G P LA N T

D IN S P EC T IO N ; C O N T R O L

C ON C R ET E - C VC A N D / OR R C C T R A N SP O R T , H A N D LIN G, IN S T A LA T ION , P R O T E C T IO N A N D C LE A N E SS
T R A N SP O R T A T ION

E IN SP EC T IO N ; C O N T R O L

C O N C R ET E - C V C A N D / OR R C C
P LA C E M EN T
IN SP EC T ION ; C O N T R O L
F

C O M P A C T IO N , P R O T EC T ION A N D C UR E R E P A IR S A N D SUR F A C E F IN IS H IN G R E P A IR S A N D R EA D IN GS A N D
C O R R EC T ION S T R EA T M E N T C O R R EC T ION S R EC O R D

G IN SP EC T IO N ; C O N T R O L

ST R UC T UR E F IN IS H ED

H IN SP EC T IO N ; C O M M IS SIO N ; A C C E P T A N C E

C ON T R O L T EC H N IC A L

Figure 33- Quality Control Actions

 MATERIAL SAMPLE STANDARD TYPE OR FREQUENCY LABORATORY TESTS OR

OR SYSTEM POINT REFFERED INTENTION EVALUATION

REINFORCING STOCKS RECEPTION EACH TRUCK JOB SITE WEIGHTLINEAR, YELD STRENGTH,

STEEL (30t) RUPTURE STRENGTH, ELONGATION, BENDING

REINFORCING STRUCTURES CONTROL 2 % OF TOTAL JOB SITE RUPTURE STRENGTH

SPLICES SPLICES

WATER BATCH CONTROL WEAKLY JOB SITE SOLIDS, pH, O2, SO4, Cl

PLANT

ADMIXTURES BATCH CONTROL ONE / 1000Kg JOB SITE SOLIDS, pH, SPECIFIC GRAVITY

PLANT

WATER STOP SUPLIER DELIVERY ONE / 200m OFFICIAL LAB. ALKALIES, HARDNESS, TENSILE STRENGTH

ELONGATION AT RUPTURE

DELIVERY ONE / 2HOURS OR CEMENT FREE LIME, FINENESS BLAINE

SUPLIER ONE / 100t FACTORY TIME OF SET, LOSS ON IGNITION

CONTROL ONE / DAILY CEMENT SiO2; Fe2O3; Al2O3; SO3; CaO;MgO; FREE LIME;

CEMENT ONE / 500t FACTORY LOSS ON IGNITION; INSOLUBLE RESIDUE;

CONTAINERS RECEPTION ONE / 100t JOB SITE TIME OF SET,RESIDUE ON # 200; # 325

SPECIFIC GRAVITY; AUTOCLAVE EXPANSION

CONTROL ONE / WEAKLY JOB SITE EXPANSION "LE CHATELIER"

BATCH COMPRESSIVE STRENGTH

ADOPTED STANDARD IN
PLANT INTER- ONE / 5000t OFFICIAL LAB.
THE COUNTRY

LABORATORY

CRUSHER PRODUCTION ONE / WEAKLY JOB SITE GRAIN SIZE; APPARENT AND ABSOLUTE DENSITIES

SYSTEM ABSORTION; FLATNESS

AGGREGATES ONE / SHIFT BATCH UMIDITY; ADJUSTMENT MIXES

BATCH CONTROL PLANT

PLANT ONE / WEAKLY JOB SITE GRAIN SIZE; APPARENT AND ABSOLUTE DENSITIES

ABSORTION; FLATNESS

CONCRETES ONE / 200m3 JOB SITE SLUMP; AIR; TEMPERATURE; SPECIFIC GRAVITY

BATCH CONTROL COMPRESSIVE STRENGTH

CVC PLANTS ONE / 2000m3 JOB SITE SLUMP; AIR; TEMPERATURE; SPECIFIC GRAVITY

COMPRESSIVE STRENGTH, MODULUS, TENSILE SPLITTING

CONCRETE BATCH CONTROL ONE / SHIFT BATCH PLANT GRAIN SIZE; CEMENT CONTENT; CONSISTENCY (VeBe)

PLANTS COMPRESSIVE STRENGTH; SPECIFIC GRAVITY

RCC DAM BODY CONTROL ONE / 100m3 DAM SITE SPECIFIC GRAVITY, COMPACTION RATIO, UMIDITY

DRLLED CORES DAM BODY CONTROL ONE / 10000m3 JOB SITE SPECIFIC GRAVITY; MODULUS; PERMEABILITY

COMPRESSIVE STRENGTH

CRUSHER PLANT INSPECTION DAILY SYSTEM CHECK LIST

BATCH PLANT INSPECTION DAILY SYSTEM CHECK LIST

Figure 34- Test plan and frequency adopted for the Capanda Dam- Angola [6]
attitude of firm but pleasantly detached authority,
An advantage of RCC and the above approach is that although endeavoring to be helpful wherever they
unacceptable material is identified early and can be properly can. For these important reasons of
removed at relatively low cost. For example, a zone supervision and training, it is usually better to include
of low-density material can be identified by nuclear these functions in the owner's or engineer's
density gage testing within a short time of placing and organization than to assign this great responsibility to
then can be re-compacted or removed prior to an outside organization over which supervision and
achieving final strength. control is difficult at best. This condition is more
It is important that qualified personnel be in important in RCC than in CVC construction due to
close contact with the mixing plant at all times to the rapid rate of concrete placed. The cost of quality
maintain water contents at the optimum level for concrete work will be least when all concerned really
compaction. The control measures that should be want it and work harmoniously together to see that
instituted in RCC construction are essentially they get it.
material-dependent. If the mixture was designed for An important early move in this direction is to
strength and consistency requirements, measurements hold pre-bid and pre-construction meetings attended
of consistency should be performed to maintain by responsible representatives of the owner and
consistency within the desired range and to expand builder, engineer, inspection and testing people, and
the judgment based on observations of the inspector materials suppliers. Thus mutual understanding of
and placing foreman. Adjustments in batch water can specifications and potential problems is promoted,
be made prior to placement when consistencies and acquaintance and communication is established.
approach control limits. Such meetings can also be helpful during
construction.
4.7 Training and Communication As part of the quality control program,
orientation and training sessions should be held for
Quality is best assured when the inspection and supervisors, inspectors, and workmen. The
testing force is well trained and skillfully supervised. differences in technique between CVC and RCC as
This includes seeing that the inspectors know at least well as granular embankments should be discussed
what they need to know and that they have the correct and understood by all. Key issues should be
explained, such as time limitations for mixing, the trial should be outside the dam body or in a less-
spreading, and compacting, and concerns about critical section of the work such as high on one
segregation, joint integrity, and curing. It should be abutment or as part of a stilling basin. The objectives
emphasized that although RCC looks and behaves of the trial are typically:
like granular fill in its early stage, it is concrete and I- To train the personnel who will work on
should be treated as carefully as conventionally the dam; only those that have worked on the full-scale
placed concrete. This includes cure, protection, and trial should be allowed to work on the initial stages of
care of compacted concrete surfaces. the RCC placement;
During construction of an RCC structure, II- To demonstrate and confirm the suitability
both the designer and inspection personnel should be of the equipment and procedures the Contractor
aware that, as with other construction methods, intends to use for mixing, handling and placing the
undesirable material will be placed occasionally. RCC (and any traditional concrete to be placed in
Field personnel should not overreact to isolated cases conjunction with it). However, the trial should not be
of placement of “rejectable” material that does not at the time that the Contractor commissions his plant;
jeopardize the overall function of the structure and all the plant should be fully operational before the
where remedial action would create a worse condition trial commences;
than leaving the material in place. Critical operations III- To evaluate the RCC mix performance,
should be identified and given more attention during i.e. segregation, proportions and compactability,
construction and inspection to prevent placement of including under unusual conditions, such as heavy
marginal material. It is very important to take in rain;
account that in RCC construction, due to its speed, the IV- To establish correlations between tests
construction planning and the quality control system done at the
must be considered in advance, and very well time of concrete placement and the properties of the
adjusted. hardened concrete.
While Quality Control (QC) is customarily
considered to be an activity performed during RCC Experience shows that it is often advantageous to
placement, it is also important that the degree of evaluate the mixture performance including the
control be considered during design, specification, consistency separately from, and in advance of, the
planning and the initial phases of construction of an full-scale trial.
RCC dam.
Rapid construction, which is one of the keys 4.9 Inspection and Testing During Placement
to the economics of RCC dams, causes quality control
of the concrete constituents and the production Quality control during RCC placement involves two
facilities to be a most important factor in ensuring operations, inspection and testing. Inspection is the
concrete quality. Once the RCC has been produced first opportunity to observe an RCC problem and
and compacted in the dam, it is expensive and institute measures to correct it. The RCC testing
unrealistic to remove the deficient material. Quality program should monitor the aggregate properties,
control after production should provide final RCC mixture proportions, fresh-concrete properties,
verification of the concrete properties. At the dam, hardened-concrete properties and in-situ compaction.
quality control of the fresh concrete must thus
emphasize test methods that can give a quick 4.10. Control of Fresh Concrete
indication of concrete quality and an indication of any
minor adjustments required to maintain the concrete Quality control of the fresh concrete at the dam
within the Specification. Further testing will of course involves careful judgment and quality consideration
be required for documentation of concrete properties, of the following components and works:
as for any other concrete construction. ƒ spreading and compaction
ƒ density and moisture content
4.8 Full-Scale Trial ƒ lift joint bonding
ƒ curing
The full-scale trial is an essential part of the QC ƒ temperature control
program. In addition to the testing of the production
and placing equipment, the testing done at this stage Density control is more important for RCC as
can form the database required to judge the RCC compared to traditional concrete. Insufficient density
quality from preliminary test data. For all but the can be the consequence of too high or too low
smallest dams, it is strongly recommended that a full- moisture, poor grading or segregation, incorrect
scale trial be constructed prior to the start of spreading, inadequate vibratory amplitude or
placement in the dam. frequency and vibration energy, delays to compaction,
The first RCC that will be placed in the dam inaccurate layer thickness or too low a number of
will be typically at the lowest point and thus amongst roller passes.
the most critical concrete in the dam. Consequently
 Density control is typically done by nuclear As with traditional concrete, the test results from the
densimeters that measure density at different depths RCC are typically evaluated statistically and
in the layer. Normal frequency of measurements compared with the design requirements. One method
ranges between one test per 200 to 500 m3 of RCC of assessing strength control of RCC is to review the
placed depending upon the size of the project. Coefficients of Variation (CV).
Quality control of intended lift joint bonding Careful curing and handling of the test
comprises the detection of possible contamination at specimens can reduce the coefficient of variations of
the surface and the identification of cold joints. The strength. Detailed investigations on such individual
first will be accomplished by specifying cleanliness of influences on the CV of the compressive in-situ
equipment at the RCC surface, method and equipment strength should be evaluated.
to be used on lift surface cleanup and preparation and
by its visual inspection prior to placing the next layer. 5 THE AUTHOR’S COMMENTS ON RCC AS A
It is common practice for large RCC projects to limit CONSTRUCTION MATERIAL
all traffic to vehicles staying on the dam or to clean
the tires of vehicles entering the concrete surface. 5.1 General
Records should be kept that identify cold joints and
that distinguish between joints which may or may not Regarding the structural behavior of RCC, the main
require special treatment. conclusions drove from the use and observations
carried out for years, are as follows:
4.11 Control of Hardened Concrete a) It is possible to construct dams of RCC with the
same watertightness as that of concrete dams built
The methods of quality control of hardened RCC in with traditional methods;
the dam are the same as those employed in the full- b) RCC dams with CVC faces, or a special RCC
scale trial. Concrete cylinders are made at the time of proportion mix, and joints having water-stops
placement, cured and then tested for strength and (including among these the dams constructed with the
modulus. Further specimens are typically obtained by Japanese method), as those with faces formed by
coring and are subject to the same tests. Core samples prefabricated concrete panels, lined with an
contain the joints between lifts that can be subjected impermeable membrane, have shown a high degree of
to detailed inspection and strength testing. watertightness;
c) The impermeability of RCC can be improved by
increasing its fines content;
d) RCC dams present less danger of cracking than
those of conventional concrete, due to their lower
shrinkage, combined in general with a reduced
modulus of elasticity and higher creep. The lower
shrinkage of roller compacted concrete originates
from its lower water and cement contents, in
comparison with those of a vibrated concrete;
e) The majority of the cracks in RCC dams can be
attributed to stresses of thermal origin in most of the
richer mixes;
f) The transverse construction joints, having
Figure 35: Coefficients of Variation obtained waterstops upstream and drainage holes, are an
during control of RCC Dams efficient system for cracking control. When distance
between joints is too large, intermediate cracks are
produced. Their width is smaller though than that of
the joints;
g) Cracks are always produced in transverse joints
where transverse sections have been deliberately
reduced, as well as in other points with smaller
transverse section, as a consequence of a lower total
tensile strength. Examples of these latter points could
be a protrusion of rock foundation, giving rise to a
stress concentration; a central spillway, or a joint on a
face of conventional concrete;
h) Cracks of RCC dams are in general vertical,
perpendicular to the axis of the dam, and do not affect
its structural stability;
Figure 36: Comparison of Coefficients of Variation i) Initial cracking can be attributed in general to
obtained during control of CVC Dams stresses induced by restraining the deformations of
thermal origin, due to the greater temperature of the accepted for comparable CVC dams and pavements.
inner concrete of the dam and that of the external However, the performance of several completed RCC
faces. dams has demonstrated the need to improve certain
Durability of RCC dams is logically related to shortcomings regarding selection of materials for
the properties of the face materials, either being of RCC, foundation treatment, structural monolithicity,
CVC or RCC. In both cases, a greater strength of the cracking and leakage prevention, when compared to
mix and a better quality of the aggregates are required the standards for CVC dams. Adequate bond,
to provide a greater durability. In the case of CVC uniformly distributed over the entire surface of each
concrete, the inclusion of air improves significantly construction joint, is essential to obtain the necessary
frost resistance and watertightness. RCC surfaces degree of elastic monolithicity in a high RCC gravity
submitted on occasions to overtopping, with great dam. Without such adequate bond, there may occur
flows running at high speed, have shown an adequate higher shear stresses than admissible and an
resistance to erosion, except in some badly compacted unacceptable risk of shearing at a weak construction
zones, such as those observed in faces built directly joint. Adequate bond at the construction joints can be
against formwork. The resistance to freezing-thawing obtained with a correct treatment. The scope of
cycles has also been very good. exploration, analyzing and rock foundations treatment
Evaluation of actual and anticipated of a high RCC gravity dam should be the same as
performance of RCC incorporated into the dam poses required for a comparable CVC dam. The impact of
issues and problems either similar as dissimilar to foundation treatment on costs and construction
those posed by CVC placed by traditional methods. schedule of the dam should not be underestimated at
The premise is that proper planning, material the time of type and layout selection of the dam. The
selection, mixture proportioning, and construction foundation should be shaped smooth since
practices were all followed as set in the contract irregularities may cause stress concentration and
documents and pointed in preceding chapters. cracking of the dam. Prevention of structural cracks in
Performance evaluation involves the verification that a high RCC dam should be a mandatory goal.
quality control operations and quality assurance Transverse construction joints for the full section of
programs were effective so that the concrete in the the dam, provided at intervals not exceeding 20m to
finished structure has appropriate properties. For 25m and along the entire length of the dam, are
example, if sulfate-resisting cement was needed, it is effective in preventing transverse cracking.
assumed that it was specified, obtained, delivered, and
used, and that it is the product intended by the 5.3 Cost
specification.
The cost of RCC is less than CVC for unit volume.
5.2 Structural and Materials Properties The cost of RCC dam can be less than other type of
dam. A large number of factors and conditions,
The comparison of important physical properties of especially site conditions, can affect cost and
RCC and CVC indicates that modern RCC is “a construction time. Past standards to choose one or
concrete” and that high and large RCC dams, of the other type of dam need to be reviewed considering all
same quality as existing major CVC dams, can be factors, conditions, time scheduled, and costs.
designed and built, provided strict quality control is
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