ROLLER COMPACTED CONCRETE

By
P.D. Arun Pandian
M.E. Structural Engineering (Ist yr)
Introduction
 Roller compacted concrete is a zero-slump concrete consisting of dense-
graded aggregate and sand, cementations materials, and water.

 It contains a relatively small amount of water, it cannot be placed by the same

methods used for conventional (slump) concrete.

 The basic difference is that roller compacted concrete is a much drier mix with
practically zero slumps.

 The properties of RCC mainly depend on quality of raw materials used, the
cementations material content, the degree of compaction and the quality
control measures.
 For effective compaction, the mix should be sufficiently dry so that it can
support the load of vibratory equipment and on the other side it should be
sufficiently wet also to allow adequate distribution of paste binder throughout
the mass to attain required density.

 The method of compaction is different than the conventional compacted

concrete and it is compacted by vibratory or pneumatic-tired rollers.
Where it is used?
 RCC is placed by asphalt pavers and compacted by vibratory rollers and
hardened into concrete.
 RCC pavements can be used where there is a need for a strong, hard, wearing
surface that will handle low-speed traffic.
 RCC for pavements is placed without forms, finishing, pointing, or surface
texturing.
 RCC pavements can be constructed more rapidly and with less labor and
expenses than traditional concrete. Because of the low water content used in
the RCC mixture and resulting low water- cementitious materials ratio, RCC
typically has strengths similar to, or greater than, conventional concrete.
Application:
RCC DAMS (RCCD)
• The main economic advantages result from the following features of RCC dams:
(i) Speed of construction: Large volumes of (low or high paste) concrete can
easily be placed with heavy equipment, thus shortening the construction period of
these dams.
(ii) Low unit costs of RCC: The unit cost of low paste mass concrete is
favorable to reduce the heat of hydration a significant portion of cement is usually
replaced by locally available pozzolanic materials or fly ash.
(iii) Heat of Hydration: Heat of Hydration plays a vital role in the place of
mass concrete hence Roller Compacted Concrete can be used.
Because of the low water content used in the RCC mixture and resulting low
water-cementitious materials ratio, RCC typically has strengths similar to, or
greater than, conventional concrete

Dam were constructed using RCC as show in figure.

Puerto Santa Cruz Dam
RCC Pavements (RCCP)
 RCC mixtures for pavements contain approximately three times as much
cementitious material as RCC mixtures for dams.
 Usually, RCC mixtures for pavements contain less cementitious materials than
conventional concrete mixtures.
 RCC pavement is much quicker to construct than conventional concrete
pavement.
 RCC pavements do not require joints, dowels, reinforcing steel, or formwork.
 RCC pavement is much stronger and durable than asphalt pavement. RCC will
not rut from high axle loads, or shove or tear from turning or braking of
operating equipment.
 It will not soften from heat generated by hot summer sun or material stored on
RCC floors (for example, compost).
 In repair and rehabilitation works RCC become a most economical and
preferred one.
• Roller Compated Technique
Materials used in RCC
 The basic material used in RCC is cement, coarse aggregate, fine aggregate,
water and chemical admixture.
(i) Coarse aggregate:
To produce high quality RCC, both the coarse and fine
aggregate fractions should be composed of hard, durable particles and the
quality of each should be evaluated by standard physical property tests.
Crushed stone are preferred in RCC as it absorbs more amount
of water than normal one,
The maximum size of aggregate used is 20mm.
(ii) Fine aggregate:
In order to improve the smoothness of the top surface of RCCP
and to obtain a closed surface, it is recommended that non-plastic fines passing
a 75-μm
It has been reported that the Increase in water content did not
significantly affect compressive strength at constant cementitious materials
content.
 (iii) Cementitious material:
 Fly Ash: Cementitious material used 11% by total mass and
20 to 30% of fly ash is used.
• (iv)Blast furnace slag and phospo-gypsum:
Blast furnace slag and phospho-gypsum (a by-product of phosphoric acid
production) were found to increase the setting time of RCC, thus allowing an
increased time for construction.
(v) Silica fumes:
It used to increase the strength and frost properties of RCC.
It is limited up to 10% by maximum.
Methods of Preparation of RCC:
Mixing of RCC using Pug mill
Preparation of ground for placing RCC
Placing and initial compaction of RCC
Materials being placed and compacted
Roller-compaction of RCC
Water and Chemical Admixtures:
 Entraining the amount of air in RCC is quite difficult, particularly having no
measurable slump.
 So air entraining admixtures is used to form a film around each bubble.
 When the quantity of water added to the RCC mixture is significantly
decreased, water tends to fill first of all cover solid surfaces.
 There is thus a competition for water between the bubbles and the solid
particles.
 It was found that attempts to entrain air in RCC mixtures can be successful if
the air-entraining agent is premixed with the cementitious paste (a mixture of
cementitious materials and water), a small portion of the coarse aggregate,
and a super-plasticizer before adding the sand.
 The addition of a set-retarding admixture can also be effective to allow a delay
of the rolling process without the formation of cold joints.
 Advantages:
 RCC has excellent durability, even under freeze-thaw conditions;
 eliminates seepage through pavement.
 It enhances construction and minimizes labor.
 It resists abrasion, eliminates need for surface course and reduces cost.
 It is so fast, easy, cheap, and durable also create a surface texture that
gives it a characteristic coarse finish.
 Disadvatages:
 RCC does not have the same appearance as other types of concrete but
is not as pretty and smooth as regular concrete.
 Heat of hydration is little high when compared to normal conventional
concrete.
 Transportation of materials is difficult.
 Material loss is high.
Journals
Evaluation of Properties of Roller Compacted Concrete Pavement (RCCP)
by S. Krishna Rao
The work presented in this paper introduces the use of Roller
Compacted Concrete Pavement (RCCP) as an alternative of
traditional Bituminous Concrete pavements that suffer from
see rutting and cracking due to heavy loading and hot weather
conditions that prevails in India.
Properties: Compressive strength (N/mm²)
% of cement @3days @7days @28days
13 20 21.11 23.11
14 24.22 26 33.11
15 25.11 27.33 36.99
16 28 29.55 38
 Flexural test (N/mm²)

%Of cement @3days @&days @28days

13 3.1 3.5 4
14 3.2 3.7 4.5
15 3.7 4.2 5.4
16 4 5 6

Split tensile Strength (N/mm²)

% 0f cement @3days @7days @28days

13 1.132 2.33 2.4
14 1.84 2.47 2.61
15 1.9 2.6 2.97
16 2.54 3.11 3.25
He concluded that
Compressive strength increases with increase in cement content.
At initial stage the increase in strength is stable but at 28 days
strength variation is quite considerable.
Flexural strength increases with increase in cement content. At
14 % cementitious content gives a flexural strength of 4.5MPa
which is suitable for rigid pavement construction in India.
Split tensile strength increases with increase in cement
content.
From the strength behavior of RCC, it can be recommended
for paving applications.
Investigating the possibility of constructing low cost roller compacted
concrete dam
by Mohamed I. Abu-Khashaba
The research was set with the objective of investigating the
possibility of constructing
Roller Compacted-Concrete Dam, RCCD, using local material to reduce
its cost.
Trial laboratory concrete mixtures were conducted to define RCCD
proportions in stage-I. Twelve mixtures with fly
ash, FA, of cement replacement percentages (0%, 50%, and 60%)
He concluded from results that
Based on lab trial mixes, using of FA, as a partial replacement of
cement, the purpose of using FA is due to its pozzolanic reaction, as well as
to reduce cement usage required especially for mass structures.
From the results obtained he concluded that to implement RCC
technology in dam construction, full scale RCC dams are required to be studied
analytically and verified with in situ data.