Mix Design

g & Construction of RCC

Wayne Adaska, P.E.

Director, Public Works
Portland Cement Association
 Mixture Design

¾ Dry enough to
support
pp vibratory y
roller
¾ Wet enough to
permit adequate
distribution of paste
 Mixture Design

¾Differs from conventional concrete pavements

–Not air-entrained

–Lower water content

–Lower paste content

–Larger
Larger fine aggregate content

–Nominal max. size aggregate

gg g +/- 5/8 in.
 Proportioning Methods

¾S
¾Several
l methods
th d available:
il bl
–Concrete
Concrete consistency tests

–Soil compaction methods

–Optimal paste volume method

–Solid suspensions model

¾Always allow time and money for field trial

 Aggregate Selection

¾ Aggregate selection
very important
¾ Responsible for mix
workability,
segregation,
ti ease off
consolidation
¾ Pre-blended
P bl d d or
stored separately
 Aggregate Selection

¾Select a sound, well-graded

g aggregate
gg g
–For stability under vibratory roller, aggregate
interlock for load transfer, highest
g density,
y
reduced segregation
¾Crushed or uncrushed g
gravel or crushed stone
¾Crushed aggregates:
–Require
Require more compactive effort
–Require more water
–Provide
P id greatert stability,
t bilit lless segregation
ti
–Provide higher flexural strength
 Aggregate Selection

¾Highway base course

course, asphalt or concrete
aggregates can be used
¾5/8 in
in. NMSA
– Provides smooth surface, reduces segregation
¾Higher fine aggregate content than conventional
– Economic advantage using non-washed and pit-run
aggregates including dense graded aggregate base
– Provide adequate stability under vibratory roller
¾2%-8% passing #200 sieve
– Supplements paste to fill voids and maintain tight surface
Optimum Combined Gradation
(Shilstone Method)

¾The Coarseness Factor Chart provides on

overview of the mixture

¾The 0.45 Power Chart shows a trend

¾Percent of aggregate retained on

individual sieves (8/18 rule) shows details
 Aggregate Gradation
Sieve Size Percent Passing Actual
in mm Minimum Maximum Gradation
1" 25 100 100 100
3/4"
3/4 19 95 100 100
1/2" 12.5 75 90 85.2
3/8" 9.5 65 85 75.0
#4 4 75
4.75 40 60 57 0
57.0
#8 2.36 25 50 43.5
#16 1.18 20 40 34.2
#30 0.6 10 30 24.3
#50 0.3 7 20 10.6
#100 0 15
0.15 5 15 21
2.1
#200 0.075 2 8 0.7
Coarseness Factor ((CF)) = % retained on 3/8 in. ÷ % retained on # 8 sieve x 100

Workability Factor (WF) = % passing #8 sieve + [ 2.5 x (lb/yd3 of cementitious

material – 564) / 94]÷÷
 Soil Compaction Method

¾Select cementitious materials

–Portland
Portland cement: Type I or II (C150 or C1157)
–Blended cement: (C595 or C1157)
–Fly Ash (C618),
(C618) Slag (C989) or silica fume
(C1240)
–Normally 400-600 lb/cy total cementitious
(12% to 17% of dry weight)
–If used,
used fly ash proportions typically 15% to
25%; silica fume typically 5% to 10%
 Soil Compaction Method

¾Determine moisture content

–Construct
Construct moisture/density curve
–Modified proctor ASTM D1557
–Assume
A a median
di cementt content
t t (e.g.
(
500 pcy)
Moisture-Density
Moisture Density Relationship
144
Dry Density (llb/cf)

143

142

141

140
2% 3% 4% 5% 6% 7% 8%
Moisture Content
Modified vs Standard Proctor
 Soil Compaction Method

¾D t
¾Determine
i cementitious
titi materials
t i l content
t t
–Use optimum moisture content
–Run cement series
• e.g., 11%, 13%, 15%, 17%
–Select cement content which yields
appropriate strength.
 Strength vs
vs. Cement Content

6,500 725
Compresssive

6,000
, 697
ngth (psi)

5,500 667
28-Day C

5 000
5,000
Stren

636

4,500 603

4,000 569
10% 12% 14% 16% 18%

Cement Content
 Admixtures

¾Retarder
¾R t d or watert reducer
d can b
be usedd tto
increase working time
¾Silica fume (7%) has resulted in
significant strength gains
¾Air entrainment not yet technologically
possible, but
p
–Experience has shown RCC can be made
freeze/thaw resistant
 Freeze-Thaw Durability
¾Field performance excellent, although not air
entrained
¾Minor surface paste (1/16”) erodes, then
stabilizes
t bili
¾RCC results variable under ASTM C666 (F/T)
and C672 (Deicer scaling)
¾Tests appear
pp to be too severe based on
actual experience
¾Durability tests used for masonry concrete
and precast units possibly more appropriate
Freeze-Thaw Durability
 Sample RCC Mix Designs

Port of Tacoma
Units Intermodal Yard CTL Mix Canada Mix
Coarse Aggregate lb/cy 1,700 2,106 2,210
Fine Aggregate lb/cy 1,700 1,378 1,338
MSA in 5/8 3/4 1/2
% Finer Than #200 % 3-7 2 1
Cement lb/cy 450 504 470
Fly Ash lb/cy 100 0 36 (silica fume)
Water lb/cy 257 211 172
Admixture oz/cwt none none 5 (WR)
w/c ratio - 0.47 0.42 0.34
Unit Weight lb/cy 154.3 152.0 153.1
C
Compressive:
i 3d
day psii 1 810
1,810 5 460
5,460 -
Compressive: 28 day psi 6,050 7,900 -
Flexural: 3 day psi 525 690 1,205
Flexural: 28 day psi 770 900 1,640
Construction
 Construction Requirements

¾Subgrade preparation
¾Mixinggpprocess
¾Transporting
¾Placing
¾Compacting
¾Jointing
¾Curingg
 Continuous Pug Mill

¾ High-volume
applications
¾ Excellent mixing
efficiency for dry
materials
¾ 250 to 500+
500 tons/hr
¾ Mobile, erected on site
 Central Concrete Batch Plant

¾ Highly accurate
proportioning
¾ Local availability
¾ Smaller output
capacity
¾ Longer mix times than
conventional concrete
¾ Frequent cleaning
¾ Dedicated production
 Dry Concrete Batch Plant

¾ Highest local availability

¾ 2-step
ppprocess
–Feed into transit
mixers
–Discharge into dumps
¾ Very slow production
¾ Frequent cleaning
¾ Segregation possible
 Dry Concrete Batch Plant

¾ Supplementary
mixer can aid in
thorough mixing and
plant throughput.
Mobile Mixers
 Transporting

¾ Rear dump trucks

normally used
¾ Minimize transport
time
¾ Covers required for
long hauls, or
h t/ i d conditions
hot/windy diti
Transporting

Load in multiple piles

 Placing

¾Layer
y thickness
–4 in. minimum
–8 in. maximum ((10 in. with heavy-duty
y yppavers))
¾Timing sequence
–Adjacent lanes placed within 60 minutes for
“fresh joint”, unless retarders used
–Multiple
Multiple lifts placed within 60 minutes for bond
¾Production should match paver capacity
–Continuous
Continuous forward motion for best smoothness
 Placing Equipment

¾ High-density
g yppavers
– Vibrating screed
– Dual tamping bars
– High
g initial density,
y, 90-95%
– Reduces subsequent
compaction
– High-volume
g placement
p
(1,000 to 2,000 cubic yards
per shift)
– Designed for harsh mixes
– Smoothest RCC surface
 Placement Equipment

Transfer equipment keeps paver fully charged

 Placing Equipment
Conventional asphalt pavers
– Provide some initial density
(80-85%)
– Relatively smooth surface

– May require modification

– Increased maintenance
 Compaction

¾ Proper compaction
is critical for strength
and durabilityy
¾ Compact to 98%
Modified Proctor
¾ Vibratory roller
¾ Rubber-tire roller
Compaction Very Important
 Construction Joints

¾ Most critical area of project

¾ Must be constructed properly for durability
¾ Ensures
E bond/interlock,
b d/i t l k so slab l b acts
t
monolithically
¾ Three
Th ttypes off construction
t ti joints:
j i t
– “Fresh joints”
– “Cold
Cold joints
joints”
– “Horizontal joints”
Fresh Joint
 Edges Critical

¾Compaction more difficult

¾Segregation more likely

¾Try to minimize number of cold joints

¾Care needed to match g

grade from cold
to fresh joint
 Edge Compaction

Compacting shoe
Edge Compaction
Avoid Edge Segregation
Matching Fresh to Cold Joint
 Cracking/Jointing
¾ Saw-cut
Saw cut joints
unnecessary for
p
performance
¾ Natural cracks provide
excellent load transfer
¾ Saw-cut joints control
cracks for aesthetic
purposes
 Natural Cracks

¾ Most economical
¾ 15 to 60 ft spacing
¾ Often first cracks
appear within 24 hours
¾ Narrow
N crackk widths
idth
¾ Seal if > 1/4 in.
¾ Provide load transfer
¾ Minimal raveling

New, Unsealed 10-yr Old

Crack Sealed Crack
 Saw-Cut Joints

¾ More aesthetically
pleasing
¾ Soff-cut
Soff cut very effective
effective,
shortly following
p
placement
¾ Need to saw within 12
hours to avoid
uncontrolled
t ll d cracking
ki
¾ 1/3 to 1/4 depth
¾ Seal joints similar to
conventional concrete
 Curing
g

¾EXTREMELY IMPORTANT
¾Ensures surface durability; reduces dusting
¾Low moisture content in RCC; no bleed water
¾Three methods:
–Moist cure
–Concrete
Concrete curing compound
–Asphalt emulsion
 Water Cure

Typically 7-day specified

 Concrete Curing
g Compound
p
¾ White-pigmented concrete
curing compounds
¾ Application rate depends
on surface texture
 Surface Texture

Intermodal Yard, TX Sludge Drying Bed, TX

Warehouse Facility, WI Honda, AL

Quality Control
 Quality Control

¾Aggregate quality
quality, gradation & moisture
¾Plant calibration
¾Density tests
¾Smoothness
¾Surface texture
¾Thickness
¾Strength
ASTM D1557
 ASTM C1435

ASTM C1435
Typically 3/8 in. over 10-ft length
 More Information

www.cement.org/pavements
 Questions?
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 Specifications for Mix Design

¾Prescriptive: Provides required properties

of a product,
product material or piece of equipment
and the method of installation.

¾Performance: Provides the required results,

criteria by which the performance will be
judged and the method by which it will be
verified.
 Prescriptive Examples

¾A
¾Aggregate
t gradation
d ti

¾Mix design including cement content

¾Type
yp of mixing
gpplant

¾Type of paver

¾Type and size of compaction equipment

¾Method of curing
 Performance Examples

¾Minimum strength

¾Minimum density

¾Production rate

¾Thickness

¾Smoothness
 Combined Specification

¾Mix design/Compressive strength

¾Type of mixing plant/Production rate

¾Type and size of compactor/Density

¾Minimum number of passes/Density