What is RCC?

What Is RCC or Roller-Compacted Concrete Pavement?

Roller-Compacted Concrete (RCC) pavement is a specialized type of concrete pavement that is placed and compacted using high-density paving equipment and vibratory rollers. It is primarily used in heavy-duty applications where strength, durability, and speed of construction are essential. RCC is stiff, has no slump, and requires a different mixing process, unlike conventional concrete pavement.

RCC Main Markets

The major market for Roller-Compacted Concrete (RCC) has most commonly been industrial and commercial facilities often for transportation, distribution, and manufacturing operations. These typical RCC projects are for constructing parking lots, distribution center yards, and other high-load pavements in similar settings. New RCC markets and applications are growing rapidly given the many benefits and advantages that roller-compacted concrete has to offer.

History Of RCC Pavements

The development of Roller-compacted Concrete dates back to the 1970s when engineers sought to find a faster and more economical method for constructing large-scale concrete pavements. The first RCC projects were undertaken for dam construction and water resource applications, where its rapid placement and excellent load-bearing characteristics proved advantageous. RCC has the durability and versatility to be utilized in freeze-thaw environments as well. Over time, the technology evolved, and RCC has found a vast spectrum of new applications, including transportation infrastructure.

RCC Mix Design

The basic ingredients of RCC are similar to conventional concrete, including aggregates, portland cement, supplementary cementing materials, chemical admixtures, and water. However, RCC has a stiffer mix with no slump, and its compressive strengths are generally higher, ranging between 4,000 to 6,000 psi (up to 10,000 psi in some cases). Flexural strengths are also in the 550-700psi range typically.

RCC requires a different mixing process due to its very dry mix. Continuous mixing plants or pug-mills are commonly used to ensure consistent results. Recent developments in portable twin shaft mixing units have also allowed batch plants to produce consistent RCC mixes.

Placement Methods of RCC

Transport and Placement

Roller-Compacted Concrete material is transported from the pugmill to the paver using dump trucks. Purpose-built, high-density asphalt-type paving equipment is used for the most consistent placement results. RCC is placed in lifts (layers) that are typically between 4 to 10 inches (100-250mm) thick and 30 feet (13m) wide.

Material Transfer Devices

For projects requiring dual lifts exceeding 10 inches, material transfer devices are recommended to feed the second lift of RCC pavement. This ensures uniformity and proper compaction.

No Forms or Hand Finishing

Unlike traditional concrete, RCC does not require the use of forms or hand finishing. This contributes to its cost-effectiveness and efficiency in construction.

Jointing

While jointing was not common in early RCC placements, current practices recommend the use of joints to control cracking and enhance the appearance of the pavement surface.

Compaction

Compaction using steel drum vibratory rollers starts immediately after RCC placement and continues until the pavement meets the required density specifications. Unlike conventional concrete, RCC does not require internal vibration for consolidation.

Curing

Curing is an essential step to prevent moisture loss and promote adequate strength gain and durability. Typically, a spray-on membrane curing compound is used for RCC.

Surface Texture

Unlike conventional concrete, RCC is not typically surface textured while in a plastic state. However, surface texture can be achieved through techniques like grinding or grooving, similar to conventional concrete pavements.

Recent Developments

Recent technological advancements have introduced opportunities to trowel and broom finish RCC surfaces using admixtures and surface sprays.

RCC Applications

Roller-Compacted Concrete is the top choice when speed of construction, strength, durability, and economy are the key requirements. Here are many of the places to find RCC applications:

Port, rail, intermodal, & military facilities
Distribution centers, parking & storage facilities
Around intersections, shoulders, turn lanes, bike paths of streets & highways
Manufacturing facilities, heavy haul roads, & scrap yards
Power plants & other industrial facilities
- Additional RCC applications may include areas like industrial slab floors, over-topping protection, airfield maintenance areas, embankment dam raise, & reservoir liners

Major Benefits of RCC

Cost-effective to alternatives
Fast construction and is open to traffic quickly
Has resistance to shoving and pushing
Long life of RCC pavement
Requires minimal maintenance
No rutting and no pot holes with RCC
Hydraulic fluid and fuel spill resistance
RCC will not get soft under high temperatures

rcc National Project Explorer

See this interactive map of roller-compacted concrete projects across North America.

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