RCC Applications

for Pavements

David R. Luhr, PhD, PE

Program Manager
Portland Cement Association

Absolute Volume

RCC

Conventional
Concrete

Cementitious

9%

10 %

Water

10 %

15 %

Fine Aggregate

34 %

23 %

Coarse Aggregate

44 %

46 %

Air

3%

6%

Total

100 %

100 %

Paste Volume

22 %

31 %

w/cm ratio

.35

.48

Fine Aggregate Ratio

.44

.33

RCC Pavement Requirements

Based on:
Smoothness (IRI)
Concrete Density (for durability, frost, permeability)
Concrete Strength (for fatigue)
Uniformity of Product (Density, Strength)
Surface Texture (for smoothness, appearance,
friction)
Class 1 High Specification
Class 2 Moderate Specification
Class 3 Low Specification

Placing Equipment

High density ABG

pavers

Vibrating screed
Dual tamping 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

Access Provided Directly Behind the ABG

Paver (Prior to Roller Compaction)

Placing Equipment
Conventional Asphalt
Pavers
Provides some initial
density (80-85%)
Relatively smooth
surface
May require
modification
Increased cleaning
and maintenance

Conventional Paver

Quebec Truck Terminal

Alternate Placing Equipment

Aggregate spreaders

Jersey spreader
Motor grader/dozer
No initial compaction
Lower quality

Off-Highway Applications
Log sort yards and haul roads
Military applications
Tank hardstands
Maintenance yards

Intermodal shipping
Truck terminals/distribution centers
Industrial operations
Parking and storage

Caycuse Log Sort Yard

Wagner L90 Log Carrier, 200k Axle Loads

Louisiana Pacific
Tacoma, WA

Fort Benning, GA
1986

Tank Trail and Hardstand

Maintenance Yard

Central Freight, Austin

New Pavement, 1987

After 10 Years of Use

Covenant Transport
Chattanooga, TN
New RCC

Existing Conventional
Concrete

Hornsby Bend, Austin

Municipal Composting

New RCC
Dillo Dirt for Sale

Old RCC

Knoxville, TN Compost Facility

Next Day Traffic

Automobile
Recycling
Facility

Storage
Bins

Wal-Mart Distribution Facility

GM Saturn Plant
Spring Hill, TN

HONDA AMERICA - ALABAMA

ALL INTERIOR ROADS--RCC

30 FT WIDE-7 DEPTH

Warehouse Facilities

Lynnterm Terminal
Port of Vancouver, BC
Interior Floor
WSI, Appleton, WI

Container Facilities

RTG Crane

Toplifter

Straddle Carrier

Bearing-Capacity Failure

Rutting in Asphalt with

Channelized Loadings

RCC at Conley Terminal Boston (built 1986)

Pier 300 - Port of Los Angeles

1998

90 Acres of RCC

CN Intermodal Yard, Calgary

1998
RCC decreased
truck wait time from
8 to 2 hours

Unsurfaced aggregate
is difficult to maneuver
and presents safety
hazard

BN Intermodal Yard, Denver

1986

35 Acres,
Up to 20 in. Thick
Straddle Carrier

Norfolk International Terminal

New Container Terminal

Projects for 2007
Port of Houston (50 acres)
Norfolk-Southern Railroad
Intermodal Terminal (Columbus,
OH) (90,000 cu. yds)

Streets and Highways

Industrial access roads
Residential streets
Highway inlays
Fast-track, high-volume intersections
Shoulders and turn lanes

Industrial Access Roads

Merridian St., Edmonton, Alb.

Tennessee DOT

Fort McMurray, Alberta

Rutted Asphalt
Milled Out

RCC Placed as Inlay

Mill & Inlay - Mississippi

During Inlay

Before

Calgary Intersection

High-Volume Asphalt Intersection Milled and

Replaced by RCC in 60-hour Weekend Construction

Columbus, Ohio City Streets

Residential Street
Alliance, NE

Subdivision Streets:
All-Weather Access

Arterial Roads
Flexural Strength of 400 psi
in 24 48 hrs
Can surface within hours

Atlanta Shoulders

RCC Performs
RCC performance unknown in 70s/80s
Gained confidence in 90s that RCC will
perform for 20+ years
PCA R&D project commissioned
Roller Compacted Concrete Pavements - A
Study of Long Term Performance
Confirmed anecdotal evidence of
performance

Surface Texture & Condition

Thin layer of surface
fines normally worn
away in first 2-3
years
Stabilizes thereafter
Coarse aggregate
exposed, but
embedded

BN Yard, Denver - 13 years

Freeze/Thaw - Deicer Scaling

Pavements exposed
to F/T and deicer
salts have fared
exceptionally well
Numerous examples
cited in report
Likely Rd., BC, built
1987.
Heavy truck braking
Chip seal worn off
No deterioration

Natural Cracks
Most economical
30 to 80 ft spacing
Often first cracks
appear within 24
hours
Narrow crack widths
Seal if > 1/8 in.
Best load transfer
Minimal ravelling

New, Unsealed
Crack

10-yr Old
Sealed Crack

Saw-Cut Joints
More aesthetically
pleasing
Soff-cut very
effective, shortly
following placement
Need to saw within
12 hours to avoid
uncontrolled cracking
1/3 to 1/4 depth

Surface Smoothness
Unsurfaced RCC can
be built for low to
medium speed traffic
High density paver
achieves good ride
quality
Joints/cracks do not
affect ride quality
99th Ave Portland, OR - 12 yrs

New Developments:
Paver Compacted
Concrete

www.cement.org/
pavements

Portland Cement Association