Guidelines for Construction of Roller-Compacted Concrete Pavements
IRC SP 68-2005 provides comprehensive guidelines for the construction of Roller-Compacted Concrete Pavements (RCCP) in India. It covers material selection, mix design, construction procedures, and quality control measures specifically tailored for RCCP, which is ideal for low-volume roads and applications where rapid construction and durability are required. This standard is essential for engineers and contractors involved in designing and building cost-effective, durable concrete pavements using roller compaction techniques.
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2005Edition
Roads and Bridges IRC- Indian road congress Category
IRC SP 68-2005 provides comprehensive guidelines for the construction of Roller-Compacted Concrete Pavements (RCCP) in India. It covers material selection, mix design, construction procedures, and quality control measures specifically tailored for RCCP, which is ideal for low-volume roads and applications where rapid construction and durability are required. This standard is essential for engineers and contractors involved in designing and building cost-effective, durable concrete pavements using roller compaction techniques.
Audience
Who Uses This Standard
Highway Engineers
Pavement Designers
Construction Contractors
Quality Control Inspectors
Project Managers
Materials Engineers
Road Maintenance Authorities
Contents
Key Topics Covered
✓Scope and applications of RCCP
✓Material specifications including cement, fly-ash, and aggregates
✓Mix design principles unique to roller-compacted concrete
✓Batching, mixing, and transporting concrete
✓Construction procedures including trial length and paving
Water content: 4% to 7% by weight; optimized by trial mixes at 0.5% intervals to achieve maximum density.
Coarse aggregates volume: 52% to 56%.
Fly ash replacement: 20% to 50% by weight of cementitious material.
Water/cementitious material ratio: Selected to achieve target flexural strength (no slump concrete).
Mix Design Procedure:
Determine target mean flexural strength (RCCP design is based on flexural strength, not compressive).
Trial mixes varying water content (4-7%) and fine aggregate volume to maximize density.
Optimize fly ash/cement ratio for strength and durability.
Construct a trial length (≥30 m) to validate mix and compaction.
Use vibratory roller passes to determine optimum compaction.
Fly Ash Requirements (IS 3812):
Property
Requirement
Fineness (m²/kg Blaine)
≥ 320
Particles retained on 45 micron
≤ 34%
Lime Reactivity (compressive) (N/mm²)
≥ 4.5
Autoclave expansion (%)
≤ 0.8
Drying shrinkage (%)
≤ 0.15
Important Notes:
RCCP is no-slump concrete, designed to support vibratory roller weight.
Water must be clean and free from harmful substances (IS 456).
Mix design is iterative with trial sections for field validation.
Cement
5Construction▼
IRC SP 68: Construction of Roller Compacted Concrete (RCC) Pavements
Key Specifications & Guidelines for Construction
Surface Preparation:
Ensure a clean, well-compacted base.
Moisture conditioning to prevent water loss from RCC mix.
Mix Transport & Placement:
Transport RCC mix using dump trucks or conveyors.
Place using pavers or spreaders maintaining uniform thickness.
Compaction:
Use vibratory rollers (usually tandem or pneumatic) immediately after placement.
Achieve target density ≥ 98% of maximum dry density.
Jointing:
Provide contraction joints at 3–4.5 m spacing.
Use saw cutting or formed joints to control cracking.
Curing:
Apply curing compound or water spray immediately after compaction.
Maintain curing for at least 7 days.
Typical Construction Parameters
Parameter
Value/Range
RCC Thickness
150 – 300 mm
Roller Speed
3 – 5 km/h
Number of Roller Passes
3 – 5 passes
Compaction Effort
≥ 98% Proctor density
flowchart TD
A[Base Preparation] --> B[Mix Transport]
B --> C[Placement by Paver]
C --> D[Compaction by Roller]
D --> E[Jointing]
E --> F[Curing]
Note: Refer to IRC SP 68 Clause 5 for detailed construction procedures and quality control measures.
6Quality Control▼
IRC SP 68: Quality Control for Roller Compacted Concrete Pavements (RCCP)
Key Specifications & Procedures:
Materials:
Cement: IS 269 (33 grade), IS 8112 (43 grade), IS 12269 (53 grade), IS 455 (Portland Slag), IS 1489 (Pozzolana).
Fly-ash: IS 3812 Grade I; key physical requirements:
Property
Requirement
Fineness (m²/kg Blaine)
≥ 320
Particles > 45 micron (%)
≤ 34
Lime Reactivity (N/mm²)
≥ 4.5
Autoclave Expansion (%)
≤ 0.8
Drying Shrinkage (%)
≤ 0.15
Aggregates: IS 383 compliant, max 25 mm size, flakiness + elongation ≤ 40%, water absorption ≤ 5%.
Mix Design:
Target mean flexural strength basis.
Water content: 4–7% by weight (optimum moisture for max density).
Coarse aggregates: 52–56% by volume.
Fly-ash replaces 20–50% cement by weight.
Grading (Table 2):
Sieve Size (mm)
% Passing
26.5
100
19.0
80–100
9.5
55–80
4.75
35–60
600 micron
10–35
75 micron
0–8
Trial Length:
Minimum 30 m trial section.
In-situ density by sand replacement method (3 samples).
Reference density = average trial density (100%).
Compaction:
Use vibratory roller (80–100 kN double drum).
Number of passes determined by trial for max density.
Preliminary and final static passes (no vibration).
Optional pneumatic roller passes (200 kN, tyre pressure ≥ 0
Frequently Asked
Popular Questions About IRC SP 68
?What types of cement and supplementary materials are permitted for RCCP under IRC SP 68?▼
Under IRC SP 68, the permitted cements and supplementary materials for Roller Compacted Concrete Pavements (RCCP) are:
Types of Cement:
Ordinary Portland Cement (OPC):
IS 269:1989 (33 grade)
IS 8112:1989 (43 grade)
IS 12269:1987 (53 grade)
Portland Slag Cement (PSC): IS 455:1989
Portland Pozzolana Cement (PPC): IS 1489 Part 1:1991 (Fly Ash based)
Sulfate Resistant Cement: IS 12230 (if soil subgrade has >0.5% soluble sulfates)
Supplementary Material:
Fly Ash: Conforming to IS 3812-1981 (Grade I), replacing 20-50% of cement by weight.
Key physical requirements (IS 3812):
Property
Requirement
Fineness (m²/kg)
≥ 320
Particles >45 micron (%)
≤ 34
Lime Reactivity (N/mm²)
≥ 4.5
Autoclave expansion (%)
≤ 0.8
Drying shrinkage (%)
≤ 0.15
Additional Notes:
Cement must be stored dry, uncontaminated, and stacked max 8 bags high.
Fly ash stockpiles should be managed to prevent dust.
Water for mixing should comply with IS 456.
This ensures durability and performance of RCCP as per IRC SP 68 guidelines.
?How is the mix design for roller-compacted concrete different from conventional concrete pavement?▼
Difference in Mix Design: Roller-Compacted Concrete Pavement (RCCP) vs Conventional Concrete Pavement
Water Content & Consistency: RCCP is a no-slump, dry mix with water content typically 4-7% by weight, optimized for maximum density and compaction. Conventional concrete uses a wetter mix with slump controlled by Abram's water-cement ratio law.
Water/Cement Ratio: Abram’s law does not apply to RCCP. Instead, water/cementitious material ratio (cement + fly ash) is selected to achieve target flexural strength.
Aggregate Proportions: RCCP coarse aggregates by volume are 52-56%, with fine aggregates adjusted to optimize strength. Conventional concrete mix has different aggregate gradation aimed at workability and strength.
Fly Ash Usage: RCCP often replaces 20-50% cement with fly ash to improve workability and durability.
Strength Basis: RCCP mix design is based on flexural strength, unlike conventional concrete which often uses compressive strength.
Moisture Content: Must be balanced to support roller weight and ensure paste distribution during compaction.
Summary Table
Parameter
RCCP
Conventional Concrete
Water Content
4-7% (no slump)
Higher, slump controlled
Water/Cement Ratio
Based on cement + fly ash
Abram’s law applies
Aggregate Volume (Coarse)
52-56%
Varies, optimized for workability
Fly Ash Replacement
20-50% by weight
Less common
Strength Basis
Flexural strength
Compressive strength
Mix Consistency
Dry, compactable by roller
Plastic, workable
This ensures RCCP is compacted by vibratory rollers immediately after laying, achieving high density and strength without conventional slump requirements.
Loading diagram...
?What are the recommended procedures for compaction and rolling to achieve maximum density?▼
Recommended Procedures for Compaction and Rolling of RCCP (IRC SP 68):
Timing: Compaction must start immediately after laying and leveling the RCC mix.
Roller Type: Use a double drum smooth wheel vibratory roller (80-100 kN).
Number of Passes: Determine during trial runs by measuring in-situ density; increase passes until maximum density is reached.
Rolling Sequence:
1 preliminary static pass (no vibration) to bed the concrete.
Vibratory passes to achieve maximum compaction.
1 final static pass (no vibration) to remove roller marks and smoothen the surface.
Edge Rolling: Start vibratory rolling from the outer edge, allowing the roller wheel to extend 25-50 mm beyond the pavement edge to confine RCCP.
Surface Finish: For high-quality surface, follow vibratory rolling with 2-3 passes of a 200 kN pneumatic tyred roller (minimum tyre pressure 0.56 N/mm²).
Water Content: Adjust water content at the plant if RCCP is too wet/dry; minor adjustments only to avoid new mix design.
Temperature & Time Constraints: Complete rolling and finishing within 90 min (concrete temp 25-30°C) or 120 min (<25°C). Stop work if concrete temp >30°C.
Summary Table:
Step
Details
Roller Type
Double drum smooth wheel vibratory (80-100 kN)
Preliminary Pass
Static, no vibration
Vibratory Rolling
Multiple passes until max density
Final Pass
Static, no vibration
Pneumatic Roller
2-3 passes for surface finish (200 kN)
Edge Rolling
Roller extends 25-50 mm beyond edge
Time Limit
≤90 min (25-30°C), ≤120 min (<25°C)
Loading diagram...
?How should trial lengths be constructed and evaluated before full-scale RCCP construction?▼
Trial Length Construction & Evaluation per IRC SP 68
Length: Minimum 30 m trial section constructed outside main works.
Purpose: Refine mix, moisture content, equipment suitability, and construction methodology.
Moisture Content: Use lab-determined optimum moisture (4-7%) for max density.
Rolling: Determine number of vibratory roller passes to achieve max compaction.
Density Testing:
Use sand replacement method with 15 or 20 cm diameter holes.
Take 3 samples spaced along a diagonal, avoiding 50 cm from edges.
Average density = reference (100%).
Approval: Only after satisfactory trial length approval proceed to main work.
Adjustments: Repeat trials if density, compaction, or mix is unsatisfactory.
Compaction: Vibratory roller (80-100 kN), plus preliminary and final static passes.
Time Limits: Complete mixing to finishing within 90-120 minutes depending on temperature.
Loading diagram...
This ensures optimized RCCP mix, compaction, and construction equipment before full-scale paving.
?What quality control tests are required to ensure compliance with the standard during construction?▼
Quality Control Tests for RCCP as per IRC SP 68
Aggregate Grading & Quality
Confirm aggregate grading conforms to Table 2 sieve analysis.
Fine aggregate: max 4% passing 75 micron sieve (natural sand), 15% for crushed sand.
Coarse aggregate: max size 25 mm, soundness loss ≤12% (Na₂SO₄) or ≤18% (MgSO₄).
Test flakiness + elongation index ≤40%.
Mix Design Validation
Trial mixes to determine optimum moisture content (4-7% water by weight).
Target mean strength based on flexural strength.
Fly ash replacement 20-50% by weight.
Trial length (≥30 m) constructed to validate mix and compaction.
In-situ Density
Sand replacement method for freshly laid RCCP.
Three density holes along diagonal; average density = 100% reference.
Field density during construction compared against reference.
Compaction Control
Use vibratory roller (80-100 kN) with passes determined from trial.
Preliminary and final static passes without vibration.
Optional pneumatic roller passes for surface finish.
Water Quality
Clean, free from harmful substances as per IS 456.