Bridge Deck Delamination Study Infrared Inspection, HR-244, 1982

The Iowa Department of Transportation is responsible for maintaining approximately 3800 bridges throughout the State. Of these bridges approximately 3200 have concrete decks. The remaining bridges have been constructed or repaired with a Portland Cement (P. C.) concrete overlay. Surveys of the overlays have indicated a growing incidence of delaminations and surface distress. The need to replace or repair the overlay may be dictated by the amount of delamination in the deck. Additionally, the concrete bridges are periodically inspected and scheduled for the appropriate rehabilitation. Part of this analysis is an assessment of the amount of delamination present in the deck. The ability to accurately and economically identify delamination in overlays and bridge decks is necessary to cost-effectively evaluate and schedule bridge rehabilitation. There are two conventional methods currently being used to detect delaminations. One is ref erred to as a chain drag method. The other a electro-mechanical sounding method (delamtect). In the chain drag method, the concrete surface is struck using a heavy chain. The inspector then listens to the sound produced as the surface is struck. The delaminated areas produce a dull sound as compared to nondelaminated areas. This procedure has proved to be very time consuming, especially when a number of small areas of delamination are present. With the · electro-mechanical method, the judgement of the inspector has been eliminated. A· device with three basic components, a tapping device, a sonic receiver, and a system of signal interpretation has been developed. This· device is wheeled along the deck and the instrument receives and interprets the acoustic signals generated by the instrument which in turn are reflected through the concrete. A recently developed method of detecting delaminations is infrared thermography. This method of detection is based on the difference in surface temperature which exists between delaminated and nondelaminated concrete under certain atmospheric conditions. The temperature difference can reach 5°C on a very sunny day where dry pavement exists. If clouds are present, or the pavement is wet, then the temperature difference between the delaminated and nondelaminated concrete will not be as great and therefore more difficult to detect. Infrared thermography was used to detect delaminations in 17 concrete bridge decks, 2 P. C. concrete overlays, and 1 section of continuously reinforced concrete pavement (CRCP) in Iowa. Thermography was selected to assess the accuracy, dependability, and potential of the infrared thermographic technique.

Experimental Use of Calcium Magnesium Acetate, HR-253, 1983

The Iowa Department of Transportation Materials Laboratory personnel announced in early 1982 a process to produce a road deicer consisting of sand grains coated with calcium magnesium acetate (CMA). From that point forward the Iowa DOT began searching for a means of economically producing CMA to their concept. During 1983 and 1984 the first attempts devised for commercially producing CMA were attempted by the W.G. Block Company, Davenport, Iowa, under Iowa Highway Research Board Project HR-253. This first attempt at commercially producing CMA was accomplished by the use of concrete transit mixer equipment. Even though this procedure proved successful in the batch mixing of CMA, the need for higher production rates to reduce the cost per ton still existed. During the fall of 1984, Cedarapids Inc, Cedar Rapids, Iowa, proposed to Iowa DOT personnel the application of their technology to a continuous mixing concept for CMA. Arrangements were made for the continuous test mixing of 60 to 100 tons of CMA/sand deicer. This report covers the production effort, description and results of procedures outlined in Cedarapids Inc's proposal of September 19, 1984. The objectives of this research were: 1. To produce the CMA/sand deicer concept on a continuous mixing basis to Iowa DOT CMA concentration levels. 2. To evaluate the results of preheating the carrying vehicle (sand) prior to CMA ingredient introduction. 3. To analyze the feasibility of production equipment and procedures necessary for portable and/or stationary applications of continuous mixing concepts.

Bridge Deck Repair Using Epoxy Resin, HR-177, 1979

Research funds were approved for the purchase of equipment designed to proportion and inject epoxy resins into delaminated areas of bridge decks. Through investigation and refining of this process, it was anticipated that a maintenance procedure would be developed to delay spalling of bridge decks by "gluing down" delaminated areas before spalling occurred.

Evaluation of Fly Ash in Portland Cement Concrete Pavement in Monona County, Iowa, HR-200, 1980

The primary objectives of this research project were: 1. Determine and recommend solutions for problems relating to shipping, storing and batching of fly ash. 2. Establish a procedure for batching, mixing and placing uniform concrete with specified air content and consistency. 3. Demonstrate that concrete of comparable quality can be produced.

Evaluation of Calcium Magnesium Acetate Deicer in Scott County, HR-253, Progress Report, 1987

The field testing of the noncorrosive alternative deicing agent, calcium magnesium acetate is described. Seventy three tons were produced of one part CMA and three parts sand deicer which was field tested on I-280 from I-80 to the Mississippi River (7,000 ADT with 50% trucks). A comparative application was made with one part sand and one part sodium chloride. The study found that CMA deicer required a longer time for the pavement to reach normal conditions, and 20-25% more CMA deicer to provide the desired deicing. It was concluded that the CMA deicer was not as dependable as the sodium chloride deicing agent, and it was more difficult to clean up the equipment for spreading the CMA deicer.

Innovative Leak Test for Pavement Joint Seals, Progress Report, HR-318, 1993

Premature failure of concrete pavement contraction joint seals is an ongoing and costly problem for the Iowa Department of Transportation. Several joint seal test sections consisting of variations in sawing methods, joint cleaning techniques, sealant installation, and sealant types have been established over the past few years. Laboratory analysis and field inspections were done as a part of the tests, and core samples were taken for laboratory adhesion pull tests. Such methods often cover specifically small areas and may not expose hidden failures. Some tests are also labor-intensive and destructive, especially that of coring. An innovative, nondestructive, broad coverage joint seal tester that yields quick results has been designed and developed for evaluation of pavement joint seal performance. The Iowa vacuum joint seal tester (IA-VAC) applies a low vacuum above a joint seal that has been spray-covered with a foaming water solution. Any unsealed area or leak that exists along the joint will become quickly and clearly visible by the development of bubbles at the leak point. By analyzing the results from the IA-VAC tests, information on the number and types of leaks can be obtained; such information will help identify the source of the problem and direct efforts toward a solution.

Use of Longitudinal Subdrains in the 3R Program, HR-509, Progress Report #2, 1981

The main consideration for base construction under the pavement, in the design of Iowa's interstate, was structural capacity. The material was dense graded with the aim of supporting the pavement and distributing the load as it is transferred to the underlying grade. The drainage characteristics of the base was apparently not given adequate consideration. On jointed portland cement concrete pavement, the water that is trapped immediately beneath the pavement causes severe problems. The traffic causes rapid movement of the water resulting in the hydraulic pressures or "pumping" (movement and redeposit of base fine material), further resulting in faulting between individual slabs. The objective of this evaluation is to determine if longitudinal subdrains are effective in preventing or reducing pumping, faulting and related deterioration. Results suggest that, based upon the flow from the outlets observed during periodic checks and evidence of water flow at the outlets, it appears that to date the subdrains are effective in draining the subbase and subgrade. Because of the limited data available at this time, however, the pavement condition and faulting results are inconclusive.

High Molecular Weight Methacrylate Sealing of a Bridge Deck, HR-2031, 1988

The Iowa Department of Transportation used a high molecular weight methacrylate (HMWM) resin to seal a 3,340 ft. x 64 ft. bridge deck in October 1986. The sealing was necessary to prevent deicing salt brine from entering a substantial number of transverse cracks that coincided with the epoxy coated top steel and unprotected bottom steel. HMWM resin is a three component product composed of a monomer, a cumene hydroperoxide initiator and a cobalt naphthenate promoter. The HMWM was applied with a dual spray bar system and flat-fan nozzles. Initiated monomer delivered through one spray bar was mixed in the air with promoted monomer from the other spray bar. The application rate averaged 0.956 gallons per 100 square feet for the tined textured driving lanes. Dry sand was broadcast on the surface at an average coverage of 0.58 lbs. per square yard to maintain friction. Coring showed that the HMWM resin penetrated the cracks more than two inches deep. Testing of the treated deck yielded Friction Numbers averaging 33 with a treaded tire compared to 36 prior to treatment. An inspection soon after treatment found five leaky cracks in one of the 15 spans. One inspection during a steady rain showed no leakage, but leakage from numerous cracks occurred during a subsequent rain. A second HMWM application was made on two spans. Leakage through the double application occurred during a rain. Neither the single or double application were successful in preventing leakage through the cracks.

Polymer Additive Ductilad D1002 in a Bituminous Seal Coat, HR-2035, 1994

Seal coat and chip seal treatments are commonly used as an economical treatment to provide a new surface to an old asphalt roadway. To be successful, the aggregate or chips must be held in place on the roadway by the asphalt binder over a long period of time. It is common, over time, that the binder becomes aged and brittle and loses its ability to be flexible and hold the aggregate in place. Modifiers have been introduced to extend the life and adhesion characteristics of asphaltic binders.

Asphalt Cement Concrete Longitudinal Joint Adhesive Crafco PN 34524 (Iowa DOT New Product C-98-7), HR-2084, 2000

The joint between two lanes of asphalt pavement is often the first area of a roadway which shows signs of deterioration and requires maintenance. As the final lift of hot asphalt is being placed in a construction project, it is being forced p against the adjoining lane of cold asphalt, forming the longitudinal joint. The mating of the two lanes, to form a high quality seal, is often not fully successful and later results in premature stripping or raveling as water enters the unsealed joint. The application of a hot poured rubberized asphaltic joint sealant along the joint face in the final stage of construction should help to form a watertight joint seal. A new product, especially formulated for the longitudinal joint in asphalt pavements was proposed to improve joint sealing. The following describes the experimental application of the new product, Crafco, PN 34524.

Dynamic Pavement Deflection Measurements, Progress Report, HR-178, 1977

The Road Rater is a dynamic deflection measuring appa-ratus for flexible base pavements. The basic operating principle of the Road Rater is to impart a dynamic loading and measure the resultant movement of the pavement with velocity sensors. This data, when properly adjusted for temperature by use of a nomograph included in this report, can be used to determine pavement life expectancy and estimate overlay thickness required. Road Rater testing will be conducted in the spring, when pave-ments are in their weakest condition, until seasonal correction factors can be developed. The Road Rater does not have sufficient ram weight to effectively evaluate load carrying capacity of rigid pavements. All rigid pavements react similarly to Road Rater testing and generally deflect from 0.65 to 1.30 mils. Research will be continued to evaluate rigid pavements with the Road Rater, however. The Road Rater has proven to be a reliable, trouble free pavement evaluation machine. The deflection apparatus was originally front-mounted, but was rear-mounted during the winter of 1977-78. Since that time, van handling has greatly improved, and front suspension parts are no longer overstressed due to improper weight distribution. The Road Rater provides a fast, economical, nondestructive test method to evaluate flexible pavements. Road Rater test data can be used to predict pavement life, set priorities for asphaltic concrete resurfacing, and design asphaltic concrete overlays. Temperature and seasonal variations significantly affect Road Rater deflection readings and must be considered. A nomograph included in this report adjusts for temperature, but does not correct for seasonal effect. Road Rater testing will be conducted in the spring until seasonal correction factors can be developed. The Road Rater has not successfully evaluated rigid pavements, but research will continue in this area. 1. Recommendations for continuing Road Rater research, evaluation and application are as follows:A computer program should be established to reduce Road Rater raw data (Range and Sensor reading) to HR-178 Road Rater Dynamic Deflections For Determining Structural Rating Of Flexible Pavements mean deflection (mils) and/or structural rating. This computer printout would be similar to present friction testing printouts, and would greatly reduce Road Rater data reduction manpower needs and costs. 2. Seasonal variation study should continue to develop seasonal correction factors. Seasonal test roads will be studied concurrently with routine testing during 1979 to develop this relationship. All Road Rater testing will be conducted in the spring until the seasonal relationship is established. 3. An asphaltic concrete overlay design method should be established based on Road Rater de-flection readings. The AASHTO Interim Guide for Design of Pavement Structures 1972 will be used as a base document for this study. 4. AASHTO Structural numbers should be compared to Road Rater Structural Ratings during 1979 on asphaltic concrete overlay projects. This analysis will enable us to refine Road Rater evaluation of flexible pavements. Roads will be tested before resurfacing and several months

Thin Bonded Concrete Overlay with Fast Track Concrete, HR-531, Condition and Performance Report, 1987

This report is a supplement to one issued in late summer 1986 which covered construction on U.S. 71, in Buena Vista County Iowa. The work involved rehabilitation of an older 20 feet wide pavement by placing a four inch thick bonded concrete overlay monolithically with two feet of widening on each side. The work was performed on one lane at a time while construction traffic and limited public traffic used the adjacent traffic lane. When work on the first lane was complete traffic was moved onto it and rehabilitation was completed on the second lane. This report covers the condition of the rehabilitated roadway in May 1987 after the first winter. The condition is described by visual observations, core conditions, and various test results including core compressive strength, direct shear tests on cores for bond strength, profilometer results and delamtect test results.

Thin Bonded Overlay Evaluation, Construction Report, HR-559, 1999

In recent years, ultra-thin whitetopping (UTW) has evolved as a viable rehabilitation technique for deteriorated asphalt cement concrete (ACC) pavement. Numerous UTW projects have been constructed and tested, enabling researchers to identify key elements contributing to their successful performance. These elements include foundation support, the interface bonding condition, portland cement concrete (PCC) overlay thickness, synthetic fiber reinforcement usage, joint spacing, and joint sealing. The interface bonding condition is the most important of these elements. It enables the pavement to act as a composite structure, thus reducing tensile stresses and allowing an ultra-thin PCC overlay to perform as intended. Although the main factors affecting UTW performance have been identified in previous research, neither the impact that external variables have on the elements nor the element interaction have been thoroughly investigated. The objective of this research was to investigate the interface bonding condition between an ultra-thin PCC overlay and an ACC base over time, considering the previously mentioned variables. Laboratory testing and full scale field testing were planned to accomplish the research objective. Laboratory testing involved monitoring interface strains in fabricated PCC/ACC composite test beams subjected to either static or dynamic flexural loading. Variables investigated included ACC surface preparation, PCC thickness, and synthetic fiber reinforcement usage. Field testing involved monitoring PCC/ACC interface stains and temperatures, falling weight deflectometer (FWD) deflection responses, direct shear strengths, and distresses on a 7.2 mile Iowa Department of Transportation (Iowa DOT) UTW project (HR-559). The project was located on Iowa Highway 21 between Iowa Highway 212 and U.S. Highway 6 in Iowa County, near Belle Plaine, Iowa. Variables investigated included ACC surface preparation, PCC thickness, synthetic fiber reinforcement usage, joint spacing, and joint sealing. This report documents the planning, equipment selection, and construction of the project built in 1994.

Ralumac Latex Modified Asphalt, HR-2041, 1994

Some asphalt roadways tend to develop wheelpath ruts over time when exposed to heavy traffic. As the rutting increases in depth, the travel comfort and levels of safety decrease. A variety of remedies involving major or minor operations can be applied to eliminate ruts and renew the roadway surface. One of the simple remedies, called Ralumac microsurfacing, involves only a longitudinal band over the rut. For better coverage, ruts are filled initially and followed by a complete thin surface wearing cover over the roadway.

Video Evaluation of Highway Drainage Systems, HR-317, 1991

Since 1978 the concept of longitudinal edge drains along Iowa primary and Interstate highways has been accepted as a cost-effective way of prolonging pavement life. Edge-drain installations have increased over the years, reaching a total of nearly 3,000 mi by 1989. With so many miles of edge drain installed, the development of a system for inspection and evaluation of the drains became essential. Equipment was purchased to evaluate 4-in.-diameter and geocomposite edge drains. Initial evaluations at various sites supported the need for a postconstruction inspection program to ensure that edge-drain installations were in accord with plans and specifications. Information disclosed by video inspections in edge drains and in culverts was compiled on videotape to be used as an informative tool for personnel in the design, construction, and maintenance departments. Video evaluations have influenced changes in maintenance, design, and construction inspection for highway drainage systems in Iowa.