s25 roller compacted concrete ltc2013
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DOT Utilization of RollerCompacted Concrete
Chris Carwie, Business Development Manager
A.G. Peltz Group LLC | Birmingham, AL
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DOT Utilization of RCC
What ?
Where ?
Why?
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What is RCC?Definition
Roller-Compacted Concrete(RCC) is a no-slumpconcrete that is compacted
by high density pavers andvibratory rollers. Negative Slump
No reinforcing steel
No finishing
Consolidated with vibratory rollers Concrete pavement placed
in a different way!
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Where? Project Feasibility
Project Size
Site Geometry Loading
Characteristics
Project End User
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Why RCC Paving?
Speed ofconstruction
Early strengthgain
Durability
Cost
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$1.89
$1.55
Nom Disc Rate=8%
$0.04 $0.05 $0.06
$0.88
$0.08 $0.12
$2.25
$1.16
$7.4
$0.20$0.41
$0.99$1.16
$2.40
$1.14
0 5 6 10 13 15 16 18 24 25 28 30 34 35 38 40 45 50
Rehabilitation Activities based on Proper Maintenance Cycles for asphalt pavements. Current year costs are inflated at 4%, Rehab costs alsoinclude other Incidental Costs (striping, mob, etc) - 40% of material costs, Traffic Control - 5% of material cost, and Engineering & Inspection - 5% ofmaterial cost
Nominal Expenditures by Pavement Type Total Cost Net Present Value
M $
M $
Asphalt is 22% more expensive than RCC throughout the life cycle ofthe road
year
Asphalt Rehab: Crack / cape sealing in years 6, 13, 16, 24, 34, 38
Microsurfacing in years 10, 28
Major rehab in year 18 (2 OLAY + PDR)
Major Rehab in year 45 (5 OLAY + 20% AGG Base repair)
RCCRehab: Patch & diamond grind at years 25, 35, 2 AC Overlay at yr 45
22 %
Why RCC?Offers Lower Life Cycle Cost
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DOT Utilization of RCC
Materials & Mix Design
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Typical Mixture Design
400 550 lbs/CY Cementitious Material.
34003700 lbs/CY Well Graded Aggregate. 20 30 gallons/CY Water.
W/C Ratio usually between 0.3 0.45.
Water amount dictated by Moisture/ DensityRelationship.
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Surface Texture
Highly dependent on aggregate gradation and binder content.
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DOT Utilization of RCC
Construction
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Continuous Mix Pug Mill
High-volume applications
Excellent mixing efficiencyfor dry materials
250 to 900+ tons/hr
Mobile, erected on site
Mobilization costs
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Transporting & Placement
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Placing Equipment
High density pavers Vibrating screed
Dual tamping bars and orpressure bars
High initial density, 90-95% Reduces subsequent
compaction
High-volume placement(1,000 to 2,000 cubic yards
per shift) Designed for harsh mixes
Smoothest RCC surface
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High Density Screed
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Compacted Edges throughthe use of Edging Shoes
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Compaction-Final Density
Final density is critical forstrength and durability
Compacted to 98%Modified Proctor
Dual Steel Drum Roller
Combination Roller
Rubber coated steel drumroller
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Concrete Curing Compound
White-pigmented
concrete curingcompounds
Apply 1 to 1.5 timesthe normal
application rate
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DOT Utilization of RCC
50th
San Angelo, TX
I-85 Interchange Lagrange, GA SR 6 Powder Springs, GA
Grape Creek Road San Angelo, TXSolms Road New Braunfels, TX
US 78 Aiken, SCWoody Hayes Drive Columbus, OH
Wistful Vista Lane Fairview, OR
I-285 Shoulder Atlanta, GA
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RCC PavementWhy are DOTs interested?
Improve Structural Capacity ofExisting Roadways
Urban/fast-track construction
Lift thickness limitations
Drop-off limitations
Maintenance of cross-traffic
Construction speed
Use RCC as base underasphalt
Success with CementStabilized AggregateBases
Stimulation of competition Lowers cost to the taxpayer
Expand the portfolio ofpavement types available
Price run-up of asphalt
binder Uncertain petroleum supply
in future
Concrete pavement at a initialprice competitive with HMA
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DOT Utilization of RCC
50th
San Angelo, TX
I-85 Interchange Lagrange, GA SR 6 Powder Springs, GA
Grape Creek Road San Angelo, TXSolms Road New Braunfels, TX
US 78 Aiken, SCWoody Hayes Drive Columbus, OH
Wistful Vista Lane Fairview, OR
I-285 Shoulder Atlanta, GA
Composite Pavements
Interstate Shoulders
Turn Lanes
Lower Volume Roadways
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DOT utilization of RCCProject Types Used to Date
Composite Pavements
Interstate Shoulders Turn Lanes
Lower Volume Roadways
T i l RCC C it
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Typical RCC CompositePavement Cross-Section
6 10 RCC Base
1 3 Asphalt
6 layer Soil Cement
(250 psi @ 7 days)Existing Subgrade / Base
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Composite Pavement History
Select cities started using RCC as a base layerover 25 years ago Portland (1985)
Fort St. John (British Columbia)
City of Edmonton (92-93)
Columbus, Ohio adopted an aggressive citystreets program in 2001 Over 50 projects to date
Various methods of treating cracks from saw andsealing to allowing to crack naturally
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RCC - City Streets Examples
99th Street Portland, OR1985 Placement
City of Edmonton
1992
Joint sealed not saw cut
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SCDOT Projects
Powell Pond Rd, Aiken County (Demo. Project) SC 5, York County US 78, Charleston County New State Road, Lexington County Greystone Boulevard, Richland County S. Beltline Boulevard, Richland County Richland Street (US78), Aiken County SC 9, Horry County S-11-171, Cherokee County
US 78 L d SC
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US 78 Ladson, SCPavement Cross-Section
10 RCC Base
2 Asphalt
6 layer Soil Cement
(250 psi @ 7 days)Existing Subgrade / Base
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US 78 Ladson, SC2009
State route with heavy truck traffic
Poor & wet subgrade/soils resultedin consistent rutting
US 78 L d SC
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US 78 Ladson, SC2009
Must be able to get compaction/density,subgrade improvement may be necessary
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US 78 Ladson Co.Completed Project
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DOT utilization of RCCProject Types Used to Date
Composite Pavements
Interstate Shoulders Turn Lanes
Lower Volume Roadways
I 285 Sh ld R l t
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Owner: Georgia DOT Use Type: State Route shoulder
Year Built: 2006
Thickness: 6 & 8 RCC
Quantity: 35 lane miles 38.500CY
PavementDesign
Information
2006 SCAN Innovation Award
Material placed on weekendsonly
Removal of shoulders on Friday
night starting 9:00 PM Had to be off the road by 5:00 AM
Monday morning ($5,000 perhour fine)
Typically 1.5-2 miles per night
AdditionalDetails
I-285 Shoulder ReplacementAtlanta, GA
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I-285 Shoulder ReplacementAtlanta, GA
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I-285 Shoulder Replacement:Completed Shoulder
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DOT utilization of RCCProject Types Used to Date
Composite Pavements
Interstate Shoulders Turn Lanes
Lower Volume Roadways
STATE ROUTE 6
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Owner: Georgia DOT
Use Type: State Route shoulderand Median
Year Built: 2006
Thickness: 7 RCC (Shoulder &Median)
Quantity: 16,500 CY
PavementDesign
Information
First use of RCC in travel way inUnited States
Project won 2007 SCAN QualityAward for concrete pavementconstruction
ADT - 17,000, 5% trucks 22 MESALS
RCC used for travel lane duringconstruction
AdditionalDetails
STATE ROUTE 6Powder Springs, GA
S
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State Route 6Powder Springs, GA
S R
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State Route 6Powder Springs, GA
DOT ili i f RCC
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DOT utilization of RCCProject Types Used to Date
Composite Pavements
Interstate Shoulders Turn Lanes
Lower Volume Roadways
Ri hl d A (US 78)
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Owner: South Carolina DOT
Use Type: US Highway
Year Built: 2009
Thickness: Milled 10 asphalt
Placed 10 RCC
Traffic: 6000 ADT, 4 lanes
Speed: 45 mph
PavementDesign
Information
Replaced 27,500 SY in 15 days
Placed 10 RCC in 1 lift
All milled areas were paved withinsame day
Maintained 1 lane open in eachdirection
Transverse Joints : 20 ft, earlyentry saw cut within 3 hours
Traffic re-opened within 24 hours
100% Diamond Ground
AdditionalDetails
Richland Ave (US 78)Aiken, SC - 2009
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RICHLAND AV. (US 78) AIKEN, SC
RICHLAND AV (US 78) AIKEN SC
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RICHLAND AV. (US 78) AIKEN, SC
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RICHLAND AV. (US 78) AIKEN, SCCompleted Surface Texture
ACTUAL RCC BIDS ARE VERY COMPETITIVE
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ACTUAL RCC BIDS ARE VERY COMPETITIVEWHEN THE MARKET IS DEVELOPED
Projects Bid to SC & GA DOT in 2006-2009
LOCATION RCC
Thickness(in)
BID QUANTITY
(CY)
BID PRICE / SY BID PRICE / SY
/ IN
US 78 Aiken Co. 10 27,050 $ 29.93 $ 2.99
Lexington/Richland Co.
10 51,500 $ 33.60 $ 3.36
Rock Hill 10 25,650 $ 33.00 $ 3.30
I-385 Lauren Co. 10 135,387 $ 22.00 $ 2.20
I-385 GreenvilleCounty
8 54,957 $ 21.85 $ 2.73
SR 6 Powder
Springs
7 16,500 $28.78
I-285 Atlanta 68
20,00018,500
$17.75$23.67
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DOT Utilization of RCCWhat have we learned?
Proper Joint construction isCritical
RCC can be diamond groundto achieve a smooth ride.
Helps improve surfacetexture.
IRI numbers in the 60s areachievable.
RCC can be milled if it is going
to be covered. Milling can cause joint
damage.
10+ RCC can cause problems
when placed with typicalequipment.
Even with best practices,
surface texture is varied andmaterial dependent
RCC can be placed in anurban environment withoutexcessive traffic disruption.
You only get one shot atdoing it right.
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DOT Utilization of RCCWhat have we learned?
Proper Joint construction isCritical
RCC can be diamond groundto achieve a smooth ride.
Helps improve surfacetexture.
IRI numbers in the 60s areachievable.
RCC can be milled if it is going
to be covered. Milling can cause joint
damage.
10+ RCC can cause problems
when placed with typicalequipment.
Even with best practices,
surface texture is varied andmaterial dependent
RCC can be placed in anurban environment withoutexcessive traffic disruption.
You only get one shot atdoing it right.
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Questions and Contact Information
Chris Carwie
AG Peltz Group, LLCccarwie@agpeltz.comwww.agpeltz.com
205.335.0579
mailto:ccarwie@agpeltz.comhttp://www.agpeltz.com/http://www.agpeltz.com/mailto:ccarwie@agpeltz.com
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