How Port Houston builds heavy-duty container terminals with roller compacted concrete

Port Houston sits 50 miles inland, yet it leads the nation in general cargo and ranks third in container volume. This video shows how roller compacted concrete (RCC) lets the port's container terminals carry extreme loads on some of the most difficult soils in the U.S. Civil engineers, contractors, DOT decision-makers and pavement specialists will see the full heavy-duty pavement system, from subgrade to surface. You'll see how engineers design for expansive clays with a plasticity index of up to 70, along with dredged soils that are unsuitable for construction. The video walks through how the pavement section is layered—lime- and cement-treated subgrade, a geotextile, 4 inches of ballast rock, 12 inches of cement-treated base and 18 inches of RCC placed in two 9-inch lifts. You'll also learn how RCC is produced in on-site pugmill plants, placed with high-density pavers and compacted to as much as 98% of reference wet density, what the design requires in terms of 5,000 psi compressive strength and 550 psi flexural strength at 28 days, and why the port omits saw-cut joints and lets the RCC develop tight, natural cracks. Each top loader wheel carries 75,000 pounds. Containers stacked five high place about 60,000 pounds on each corner. On shifting soils, conventional roadway pavements cannot carry these loads without serious damage and disruptions to port operations. RCC needs no forms or reinforcement. It also gains enough strength to support construction traffic within three to four days. Port Houston has placed nearly 500,000 cubic yards of RCC since 2008, giving it a proven record of durable, high-performance pavement that keeps cargo moving. Subscribe to the RCC Pavement Council channel for more project insights and RCC construction guidance. Tell us in the comments where your firm or agency is considering RCC for heavy-duty pavement. #RollerCompactedConcrete #RCC #PortHouston #ConcretePavement #HeavyDutyPavement