What is Roller-Compacted Concrete (RCC)?
Roller-compacted concrete (RCC) is a type of concrete produced by mixing aggregate with a suitable amount of water and cement at a ready-mix concrete plant. It has a zero slump due to its low water content. With approximately 40% less water compared to conventional concrete mixes, RCC achieves a water/cement ratio as low as 0.30. This results in a 70-80% increase in compressive strength at 28 days compared to traditional concrete.
RCC provides up to three times the strength of conventional (wet) concrete. Due to its dry consistency, RCC is transported by dump trucks and laid and compacted using road construction equipment.
Ref: Türk Çimento
History of Roller-Compacted Concrete
The roller-compacted concrete technique was first used in 1940 at Washington Airport in the United States. Its use became more widespread in the 1970s due to the global oil crisis, particularly in the United States and Canada. In Europe, the technique was first applied in Spain during this period. Today, RCC is widely used in various applications.
In Turkey, the initial examples of RCC were in dam applications. The country is home to Europe’s tallest RCC dam, Çetin Dam, with a height of 165 meters in Siirt.
Ref: Çetin Dam, Limak
Applications and Advantages of Roller-Compacted Concrete
RCC is used in military bases, industrial areas, storage facilities, ports, and roads. It offers several technical and economic advantages compared to alternatives:
- No Reinforcement Needed: RCC does not require reinforcement, making it faster to construct.
- Rapid Traffic Opening: RCC surfaces can be opened to traffic quickly.
- Minimal Surface Treatment: RCC does not require additional surface treatments.
- Cost-Effective: RCC is generally more economical.
- Environmental Benefits: Its light-colored surface improves traffic safety and provides energy savings for lighting in rural areas.
Even without finishing surface treatments, RCC provides a roughness comparable to asphalt hot mix roads. Various studies show that the skid resistance of RCC roads is similar to that of asphalt hot mix roads. With additional surface texturing, RCC is a safe option for high-speed roads such as highways.
RCC has nearly four times fewer voids compared to traditional concrete. When properly designed and constructed, RCC has about 1.5% by volume of voids. Unlike traditional concrete, the voids in RCC are independent of each other.
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Ref: Türk Çimento
Due to its lower void ratio and independent voids, RCC offers higher freeze-thaw resistance compared to alternatives. It is particularly suitable for cold climates and regions with significant temperature fluctuations between day and night. The low void ratio gives RCC high durability.
Conclusion
Roller-Compacted Concrete (RCC) has been used worldwide for over 80 years. It combines the construction speed and ease of flexible pavements with the high load-bearing capacity and durability of rigid pavements. RCC is an ideal solution for many applications, including ports, industrial areas, and military bases.
Today, RCC pavements, which can be constructed and opened to traffic within a day, successfully serve even in areas exposed to heavy loads. RCC is also commonly used in dams, including Turkey's first two tallest RCC dams in Europe.
With its high strength, durability, and quick construction benefits, RCC remains a permanent and practical solution worldwide.