Mix Design

g & Construction of RCC

Wayne Adaska, P.E.

Director, Public Works
Portland Cement Association

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

Mixture Design
Differs 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
S
Several
l methods
th d available:
il bl
Concrete
Concrete consistency tests
Soil compaction methods
Optimal paste volume method
Solid suspensions model

Always allow time and money for field trial

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

Aggregate Selection
Select a sound, well-graded
g
aggregate
gg g
For stability under vibratory roller, aggregate
interlock for load transfer, highest
g
density,
y
reduced segregation

Crushed or uncrushed g
gravel or crushed stone
Crushed aggregates:
Require
Require more compactive effort
Require more water
Provide
P id greater
t stability,
t bilit lless segregation
ti
Provide higher flexural strength

Aggregate Selection
Highway base course
course, asphalt or concrete
aggregates can be used
5/8 in
in. NMSA
Provides smooth surface, reduces segregation

Higher 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

2%-8% passing #200 sieve

Supplements paste to fill voids and maintain tight surface

Optimum Combined Gradation

(Shilstone Method)
The Coarseness Factor Chart provides on
overview of the mixture
The 0.45 Power Chart shows a trend
Percent of aggregate retained on
individual sieves (8/18 rule) shows details

Aggregate Gradation
Sieve Size
in
mm
1"
25
3/4"
3/4
19
1/2"
12.5
3/8"
9.5
#4
4 75
4.75
#8
2.36
#16
1.18
#30
0.6
#50
0.3
#100
0 15
0.15
#200
0.075

Percent Passing
Actual
Minimum Maximum Gradation
100
100
100
95
100
100
75
90
85.2
65
85
75.0
40
60
57 0
57.0
25
50
43.5
20
40
34.2
10
30
24.3
7
20
10.6
5
15
21
2.1
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

Select 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

Determine 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
Dry Density (llb/cf)

144
143
142
141
140
2%

3%

4%

5%

6%

Moisture Content

7%

8%

Modified vs Standard Proctor

Soil Compaction Method

D t
Determine
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.

28-Day C
Compresssive
Stren
ngth (psi)

Strength vs
vs. Cement Content
6,500

725

6,000
,

697

5,500

667

5 000
5,000

636

4,500

603

4,000
10%

569
12%

14%

Cement Content

16%

18%

Admixtures
Retarder
R
t d or water
t reducer
d
can b
be used
d tto
increase working time
Silica fume (7%) has resulted in
significant strength gains
Air entrainment not yet technologically
possible, but
p
Experience has shown RCC can be made
freeze/thaw resistant

Freeze-Thaw Durability
Field performance excellent, although not air
entrained
Minor surface paste (1/16) erodes, then
stabilizes
t bili
RCC results variable under ASTM C666 (F/T)
and C672 (Deicer scaling)
Tests appear
pp
to be too severe based on
actual experience
Durability tests used for masonry concrete
and precast units possibly more appropriate

Freeze-Thaw Durability

Sample RCC Mix Designs

Port of Tacoma
Units Intermodal Yard
Coarse Aggregate
lb/cy
1,700
Fine Aggregate
lb/cy
1,700
MSA
in
5/8
% Finer Than #200
%
3-7
Cement
lb/cy
450
Fly Ash
lb/cy
100
Water
lb/cy
257
Admixture
oz/cwt
none
w/c ratio
0.47
Unit Weight
lb/cy
154.3
C
Compressive:
i
3d
day
psii
1 810
1,810
Compressive: 28 day
psi
6,050
Flexural: 3 day
psi
525
Flexural: 28 day
psi
770

CTL Mix
2,106
1,378
3/4
2
504
0
211
none
0.42
152.0
5 460
5,460
7,900
690
900

Canada Mix
2,210
1,338
1/2
1
470
36 (silica fume)
172
5 (WR)
0.34
153.1
1,205
1,640

Construction

Construction Requirements
Subgrade preparation
Mixing
gp
process
Transporting
Placing
Compacting
Jointing
g
Curing

Continuous Pug Mill

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

Central Concrete Batch Plant

Highly accurate
proportioning
Local availability
Smaller output
capacity
Longer mix times than
conventional concrete
Frequent cleaning
Dedicated production

Dry Concrete Batch Plant

Highest local availability
pp
process
2-step
Feed into transit
mixers
Discharge into dumps
Very slow production
Frequent cleaning
Segregation possible

Dry Concrete Batch Plant

Supplementary
mixer can aid in
thorough mixing and
plant throughput.

Mobile Mixers

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

Transporting

Load in multiple piles

Placing
Layer
y thickness
4 in. minimum
8 in. maximum ((10 in. with heavy-duty
y
yp
pavers))

Timing sequence
Adjacent lanes placed within 60 minutes for
fresh joint, unless retarders used
Multiple
Multiple lifts placed within 60 minutes for bond

Production should match paver capacity

Continuous
Continuous forward motion for best smoothness

Placing Equipment
High-density
g
yp
pavers

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
Proper compaction
is critical for strength
and durabilityy
Compact to 98%
Modified Proctor
Vibratory roller
Rubber-tire roller

Compaction Very Important

Construction Joints
Most critical area of project
Must be constructed properly for durability
Ensures
E
bond/interlock,
b d/i t l k so slab
l b acts
t
monolithically
Three
Th
ttypes off construction
t ti joints:
j i t
Fresh joints
Cold
Cold joints
joints
Horizontal joints

Fresh Joint

Edges Critical
Compaction more difficult
Segregation more likely
Try to minimize number of cold joints
Care 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
Saw-cut
Saw cut joints
unnecessary for
p
performance
Natural cracks provide
excellent load transfer
Saw-cut joints control
cracks for aesthetic
purposes

Natural Cracks
Most economical
15 to 60 ft spacing
Often first cracks
appear within 24 hours
Narrow
N
crack
k widths
idth
Seal if > 1/4 in.
Provide load transfer
Minimal raveling
New, Unsealed
Crack

10-yr Old
Sealed Crack

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

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

Water Cure

Typically 7-day specified

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

Surface Texture

Intermodal Yard, TX

Warehouse Facility, WI

Sludge Drying Bed, TX

Honda, AL

Quality Control

Quality Control
Aggregate quality
quality, gradation & moisture
Plant calibration
Density tests
Smoothness
Surface texture
Thickness
Strength

ASTM D1557

ASTM C1435
ASTM C1435

Typically 3/8 in. over 10-ft length

More Information

www.cement.org/pavements

Questions?
Discover how beautiful concrete can be

Specifications for Mix Design

Prescriptive: Provides required properties
of a product,
product material or piece of equipment
and the method of installation.
Performance: Provides the required results,
criteria by which the performance will be
judged and the method by which it will be
verified.

Prescriptive Examples
A
Aggregate
t gradation
d ti
Mix design including cement content
Type
yp of mixing
gp
plant
Type of paver
Type and size of compaction equipment
Method of curing

Performance Examples
Minimum strength
Minimum density
Production rate
Thickness
Smoothness

Combined Specification
Mix design/Compressive strength
Type of mixing plant/Production rate
Type and size of compactor/Density
Minimum number of passes/Density