City CouncilMarch 22, 2011

Roller Compacted Concrete

• What is Roller Compacted Concrete (RCC)

• Where has RCC been used

• RCC Construction Process

• 50th Street & Grape Creek Bid Tab

• Street Life Cycle

Roller Compacted Concrete

RCC Pavement

• No Slump

• Consistency of damp gravel

• No forms

• No reinforcing steel

• No finishing

• Placed with asphalt pavers

• Compacted with vibratory rollers

• Normal cement hydration

• Low W/C ratio = limited shrinkage cracks

Reynoldsburg, OH

RCC Construction Projects

Street Projects

• Collector & Residential

• Several in S. Carolina

• 100+ in Columbus, OH

• S. Carolina DOT – 8 Projects

• Interstate Projects

• I-285 Atlanta, GA

• I-385 Greenville, SC

Aiken, SC

RCC Construction Projects

S. Carolina DOT US Hwy 2009

• 10” RCC reconstruction

• 6000 ADT, 4 lanes

• 45 mph

• Replaced 1 mile in 15 days

• Re-opened in 24 hours

RCC Construction Projects

Ohio State University 2002

• 8” RCC reconstruction

• 150 buses/day

• Reconstructed in 1 weekend

• RCC selected for fast

construction process to

complete by 1st football game

RCC Construction Process

•Mid size applications

•200 to 300 tons/hr

•Available at some locations

•Fixed locations

•Capacity reduced due to low

water content of mixture

Central Mix

RCC Construction Process

•High-volume applications

•Excellent mixing efficiency

for dry materials

•250 to 900+ tons/hr

•Mobile, erected on site

•Mobilization costs

Continuous Flow Pugmill

RCC Construction ProcessAsphalt Paver Placement

• High density

• High initial density (85% to 95%)

• Smooth surface depends on initial density

• High-production (1900 LF/day)

• Max lift thick – 8 to 10 in. Lane Ave – Columbus, OH

RCC Construction ProcessAsphalt Paver Placement

• Proper compaction is critical for strength and durability

• Compact to 98% of modified proctor

• 10 to 12 Ton vibratory roller

• Eliminate long. cold joints through compaction process

Reynoldsburg, OH

RCC Construction ProcessRCC Asphalt

RCC

Diamond

Ground

RCC

Diamond

Ground

Conventional

Concrete

Conventional

Concrete

75 Year Useful Life Maintenance Cost Asphalt RCC

Sealcoat $939,680.28 $0.00

(Every 8yrs)

Mill & Overlay $6,556,466.24 $0.00

(Every 24yrs)

Overlay $0.00 $1,416,103.69

(RCC at 60yrs)

Maintenance Cost $7,496,146.52 $1,416,103.69

(75yrs)

Asphalt Street Life Cycle

0

5

10

15

20

25

0 25 50 75

Time (Yrs)

Use

ful

Lif

e (Y

rs)

50th & Grape Creek Bid TabPrice Construction Reece Albert

50th $2,267,261.73 $2,353,428.01

Grape Ck “A” $1,431,937.80 $1,174,202.99

Grape Ck “B” $1,352,668.32 $1,193,184.85

“A”= Asphalt “B”= Roller Compacted Concrete

50th & “A” $3,699,199.53 $3,527,631.00

50th & “B” $3,619,930.05 $3,546,612.86

Difference $79,269.48 $18,981.86

Roller Compacted Concrete

Questions