POLYGON MACHINE
ROLLER COMPACTED CONCRETE BATCHING PLANT (RCC)
Roller-compacted concrete (RCC) is a zero-slump, high-density concrete placed with asphalt-type paving equipment and compacted by vibratory rollers. Its mix contains much less water than conventional concrete, yielding a very stiff, low-slump material. RCC offers high strength, durability and a long service life. It is often used in heavy-duty pavements (ports, airports, industrial yards), dam and reservoir construction, and other large-scale projects. Unlike poured concrete, RCC requires no formwork, reinforcement or external vibration during placement, and can be trafficked within days. These properties make RCC an economical and fast-construction alternative to asphalt or conventional concrete in many contexts.
overvıew of ROLLER COMPACTED CONCRETE BATCHING PLANT (RCC)
RCC’s unique characteristics arise from its mix design and placement method. The dry, “no-slump” RCC mix is placed by asphalt pavers (not slip-form concrete pavers) and compacted in place. Once mixed, RCC cannot be transported long distances in standard mixer trucks or pumped like fluid concrete. Instead, it is typically hauled in dump trucks and laid in thick layers (often 15–25 cm thick) before immediate compaction with heavy rollers. A key distinction is that RCC is engineered for density and strength through compaction, rather than flowability. For this reason, RCC production demands specialized batching plants and mixers that can homogenize a dry, aggregate-rich mix efficiently, unlike the batch systems used for ready-mix concrete.
Why are horizontal low-level silos ideal for sites with height restrictions?
Because they are much shorter, often only a few meters high, making them suitable for urban or indoor locations with limited vertical space.
How does the footprint of a horizontal silo compare to a vertical silo?
A horizontal silo requires more ground area for the same capacity, while a vertical silo saves ground space by using height.
Can horizontal silos be installed under large sheds or structures?
Yes, their low profile allows them to fit under sheds or blend into environments with minimal visual impact.
Which silo type stores more cement per square meter of site area?
A vertical silo can store more cement per square meter because of its tall, upright design.
Why choose Polygon Machine?
Polygon Machine delivers certified quality (TSE & ISO 9001), global expertise, and durable solutions from 30 m³/h to 240+ m³/h. Polygonmachine is a trusted partner in both compact and large-scale projects.
What batching plant types are available?
Stationary, mobile, and compact plants—plus cement silos, feeders, and dosing units. Every system is customizable to match your space, capacity, and automation needs.
How is long-term support handled?
Polygon Machine ensures fast setup, training, and after-sales service, minimizing downtime. All plants include modern automation and safety features for easy, efficient use.
overvıew of ROLLER COMPACTED CONCRETE BATCHING PLANT (RCC)
Roller-compacted concrete (RCC) is a zero-slump, high-density concrete placed with asphalt-type paving equipment and compacted by vibratory rollers. Its mix contains much less water than conventional concrete, yielding a very stiff, low-slump material. RCC offers high strength, durability and a long service life. It is often used in heavy-duty pavements (ports, airports, industrial yards), dam and reservoir construction, and other large-scale projects. Unlike poured concrete, RCC requires no formwork, reinforcement or external vibration during placement, and can be trafficked within days. These properties make RCC an economical and fast-construction alternative to asphalt or conventional concrete in many contexts.
RCC’s unique characteristics arise from its mix design and placement method. The dry, “no-slump” RCC mix is placed by asphalt pavers (not slip-form concrete pavers) and compacted in place. Once mixed, RCC cannot be transported long distances in standard mixer trucks or pumped like fluid concrete. Instead, it is typically hauled in dump trucks and laid in thick layers (often 15–25 cm thick) before immediate compaction with heavy rollers. A key distinction is that RCC is engineered for density and strength through compaction, rather than flowability. For this reason, RCC production demands specialized batching plants and mixers that can homogenize a dry, aggregate-rich mix efficiently, unlike the batch systems used for ready-mix concrete.
What is Roller-Compacted Concrete (RCC)?
RCC is a zero-slump, high-density concrete that is placed with asphalt-type paving equipment and compacted by vibratory rollers.
How is RCC different from conventional concrete?
RCC contains much less water, has a very stiff mix with no slump, and requires no formwork, reinforcement, or external vibration during placement.
Where is RCC commonly used?
RCC is widely applied in heavy-duty pavements (ports, airports, industrial yards), as well as in dam and reservoir construction, and other large-scale projects.
Why does RCC need special batching plants?
Because RCC is a dry, aggregate-rich mix that cannot be pumped or transported in standard mixer trucks, it requires specialized batching plants and mixers for efficient production.
Technical Differences:
RCC vs. Conventional Concrete
The material properties of RCC differ markedly from ordinary Portland concrete. RCC uses a higher proportion of coarse and fine aggregates and less cementitious paste, resulting in a very low water–cement ratio and essentially zero slump. As one UK technical report notes, RCC “does not flow like conventional concrete” and “contains much less water than a conventional mix, [making] the mix … drier and ha[ving] no slump”.
This contrasts with traditional concrete mixes, which typically have 1–4 inches of slump for workability. Because RCC is so stiff, it relies on its inherent structural integrity for placement. During paving, the weight of the concrete itself and the rollers, not internal vibration, achieves compaction. In practice, RCC pavements are immediately compacted by vibratory drum rollers or pneumatic-tyred rollers until they reach the specified density.
These differences affect material handling and construction. Conventional concrete is poured or pumped, then often requires formwork and external vibration (internal pokers) to settle, and cures gradually. In contrast, RCC is placed “stiff” and gains much of its strength quickly.
In summary, compared to normal concrete, RCC is an almost “dry” concrete that is mixed and placed differently. It is not transportable in regular mixer trucks or handled like a fluid. These fundamental differences mean that an RCC batching plant must be designed to mix and deliver a very stiff mix continuously and reliably, unlike a standard ready-mix plant.
BATCHING PLANT TYPES:
RCC VS. CONVENTIONAL PLANTS
Mixer Type and Material Handling
RCC batching plants are specialized facilities that differ from traditional concrete plants in mixer type, automation, and material handling. A typical RCC plant uses a twin-shaft continuous mixer or high-speed paddle mixer to handle the stiff mix.
Such mixers are effective at blending large, coarse aggregates with cementitious materials. Industry literature highlights that twin-shaft continuous mixers are the most efficient choice for producing RCC in a continuous or large-batch mode.
By contrast, conventional ready-mix plants often use planetary or twin-shaft batch mixers that produce discrete batches of more fluid concrete. In practical terms, an RCC plant will continuously feed and mix ingredients at high volume, aiming to supply the paver without interruption.
Capacity and Productivity
Capacity and productivity also distinguish RCC plants. Because RCC construction often involves paving many thousands of cubic meters quickly, RCC plants are built for high throughput. Manufacturer data indicates road-specific RCC mixing plants can output on the order of hundreds of tons per hour.
For instance, one plant maker reports an RCC plant capable of about 800 tons of RCC per hour using a continuous twin-shaft mixer. This is substantially higher than a typical batch plant’s output per mixer. Likewise, RCC plant layouts include multiple large aggregate bins, high-capacity conveyors and multiple cement silos to ensure a steady supply.
By comparison, a standard ready-mix plant handling conventional concrete typically produces in discrete batches (often 8–12 m³ per batch) and alternates loading of mixer trucks rather than feeding a continuous paver.
Polygon Machine’s Role
In practice, Polygon Machine is one of the few firms expressly marketing RCC plants. The company’s literature describes its RCC batching plant as designed “for quickly producing large quantities” of high-density concrete.
Polygon Machine highlights that its RCC plants facilitate rapid project schedules and material efficiency by continuously blending and delivering the mix.
While Polygon Machine is featured here as a representative supplier, it should be noted that RCC plants may be custom-built by various manufacturers. Polygon Machine underscores that RCC plants incorporate heavy-duty mixers and precision controls to handle the demand.
EFFICIENCY, COST AND
LIFECYCLE ADVANTAGES
Operational Efficiency and Plant Performance
One of RCC’s main attractions is its operational efficiency and cost-effectiveness relative to traditional concrete or asphalt pavements. Economically, RCC often offers lower life-cycle costs despite similar or slightly higher initial material costs.
Comparing plant efficiency, RCC batching plants can often produce a higher continuous output than a batch plant running intermittent loads. A continuous twin-shaft mixer can run steadily as long as materials flow, minimizing idle time.
In contrast, conventional plants load one truck, mix a batch, then break before the next load. Thus, on a major paving project, an RCC plant may supply material more rapidly and with fewer delays.
Capital Cost and Material Savings
However, this comes with higher initial capital cost: RCC plants (like polygonmachine’s model) feature more automation and larger mixers, making them relatively expensive to build. The trade-off favors large, continuous projects: over a long highway or dam pour, the cost per cubic meter of production and placement can be lower with RCC.
On the material side, RCC’s leaner mix can reduce cement usage and eliminate reinforcing steel and complex forming. This further cuts material cost. Moreover, RCC pavements reduce the need for expensive surface treatments or high-maintenance asphalt overlays.
For example, the Polygon Machine report highlights up to 30% life-cycle cost savings by switching from asphalt to RCC.
Lifecycle Benefits and Long-Term Advantages
In addition, RCC pavements can improve fuel economy for vehicles (due to their high stiffness) and even support recycling at end-of-life (the rigid concrete can be crushed and reused).
In summary, RCC batching plants demand higher-capacity equipment and precise control, which increases upfront investment. However, their high throughput and the durability of RCC can provide significant efficiency and cost advantages on large-scale projects.
These advantages are most pronounced in heavy-duty or high-traffic applications, justifying RCC for major infrastructure over conventional methods.
Applications and Regional Use Cases
RCC has been widely adopted in regions seeking durable, rapid-build pavements and dam structures. In Europe, interest has grown for motorways, bridges, and industrial pavements. The UK’s Britpave initiative notes that RCC is now included in highway design guidelines, citing its suitability for heavy truck lanes, motorway widening and other scenarios.
RCC in Europe
RCC has been widely adopted in regions seeking durable, rapid-build pavements and dam structures. In Europe, interest has grown for motorways, bridges, and industrial pavements. The UK’s Britpave initiative notes that RCC is now included in highway design guidelines, citing its suitability for heavy truck lanes, motorway widening and other scenarios.
British experience shows RCC “combines the strength… of concrete with the economy and simplicity of asphalt,” and that high-density pavers can lay RCC up to 250 mm thick in wide lanes.
RCC in Eastern Europe
In Eastern Europe, countries like Lithuania have started applying RCC for industrial yards and rural roads. A recent Lithuanian study reported its first major RCC project in an industrial zone, highlighting RCC’s fast construction and high load capacity. The authors noted that RCC’s workability decreases quickly once mixed, so they employed a mobile batch plant on site to minimize transport time.
This use in cold-climate northern Europe demonstrates RCC’s versatility; its low-permeability also confers frost resistance, often without needing air entrainment.
RCC in the United States and Hydraulic Construction
In the United States, RCC has been used for ports, airports, military bases and highways. The U.S. Federal Highway Administration reports RCC applications in heavy-duty pavements (ports, intermodal yards, airfields) as well as lower-volume roads.
American contractors value RCC for rapid placement: U.S. case studies often cite job sites where miles of pavement were laid overnight, compared to days for cast-in-place concrete. These projects leverage RCC plants’ output to finish layers quickly.
RCC has also been used in dam and hydraulic construction across the U.S. (e.g., service dams and spillways), since its zero-slump mix is ideal for massive pours. In all cases, U.S. practitioners confirm that continuous mixing and paver placement make RCC “fast and economical” once proper batching facilities are in place.
Comparative Overview and Table
In practice, choosing an RCC batching plant versus a standard concrete plant depends on project needs. The table below contrasts RCC plants with other common concrete production methods:
| Feature / Plant Type | RCC Batching Plant | Standard Ready-Mix Plant | Mobile / Volumetric Mixer |
|---|---|---|---|
| Mixer & Batching Method | Continuous twin-shaft or paddle mixer; continuous feed of materials | Batch mixer (twin-shaft or pan) producing discrete loads | On-truck drum mixer; mixes on-site |
| Concrete Slump (Fluidity) | Essentially zero – very stiff, “dry” mix | Medium slump (typically 1–4″ for workability) | Adjustable slump (0–6″, as needed) |
| Production Output | Very high (often 500–800 tonnes/hr) in continuous flow | High (hundreds of m³/day) in intermittent batches | Lower (limited by truck size, typically <200 tonnes/day) |
| Placement Equipment | Asphalt-style pavers + vibratory rollers | Concrete pavers (slipform, curb machines) or pump/lugger | Direct discharge or small pump |
| Typical Applications | Heavy-duty pavements (ports, highways), dam bases, industrial slabs | General construction (roads, buildings, foundations) | Small-scale work; remote or on-demand jobs |
| Formwork / Reinforcement | None required for pavement placement | Formwork and reinforcement often needed | None (mix on site) |
| Material Handling | Automated precise dosing of dry mix; continuous weighing | Standard batching with water; batch quality checks | Flexible loading of ingredients; lower control |
| Cost Profile | Higher capital cost (complex plant), but high throughput and low life-cycle pavement cost | Moderate capital; well-known technology | Low capital; higher variable cost per m³ |
| Mobility & Flexibility | Generally stationary or semi-mobile (site-specific) | Stationary or portable batch plants | Highly mobile (truck/trailer unit) |
This comparison underscores that RCC plants are specialized for speed and volume with a very stiff mix, whereas conventional plants balance flexibility and mix fluidity.
Conclusion
Roller-compacted concrete represents a distinct approach to paving and large-area concrete construction. Compared to standard concrete, RCC requires specialized batching plants built for continuous, high-capacity mixing of a near-dry mix. These plants differ in mixer design, automation and throughput.
The benefits of RCC – rapid placement, high early strength, minimal maintenance and long lifespan – often outweigh its higher plant cost for large projects in Europe, North America and the Middle East.
Real-world case studies confirm RCC’s efficiency: for example, UAE projects report 20–30% cost savings and next-day traffic opening compared to asphalt. In the U.S. and UK, RCC is now incorporated in highway standards for heavy applications.
The principal takeaway is that when heavy pavement demand aligns with high-volume requirements, an RCC batching plant can deliver significant advantages in productivity and lifecycle economy. Companies like Polygonmachine provide the specialized equipment to exploit these benefits, delivering automated RCC plants that optimize mix consistency and speed.