RCC Pavement Success at Mobile Container Terminal

Ground was broken at Mobile Container Terminal in Alabama during October 2006, with construction of the backlands commencing in November 2007. The pavements were designed as full depth asphalt concrete (AC) to support the proposed reach stackers, as well as other terminal traffic. Potential plans to introduce rubber tired gantry cranes (RTGs) in the future would require the construction of portland cement concrete runway beams, cut into the AC pavement. Roller compacted concrete (RCC) was considered as a cost competitive paving option, eliminating the need to introduce the runway beams at a later date. Preliminary analysis indicated that this was feasible and the bidding contractors were encouraged to submit an alternative for a roller compacted concrete pavement option for comparison purposes. The value engineering process demonstrated that a roller compacted concrete pavement was less expensive than the AC option. Paving of the initial section of the first phase commenced in May 2008, and the terminal was opened for business in September of the same year. A final section of Phase 1 was completed in March 2009. This paper discusses the two alternative pavement systems, including the material properties assumed for each. The construction methods adopted for the final RCC pavement are described for both the single and double lift areas, along with the limited number of problems that were encountered along the way. The paper also covers the mix design process and the testing used for quality control. It summarizes the results from this testing, and includes verification of in-place properties, comparing design assumptions to those actually achieved. From the perspective of the pavement designer and the operator the RCC pavements are proving to be a success at Mobile Container Terminal.