Applications for Reuse of Lime Sludge from Water Softening, TR-535, 2005

Lime sludge, an inert material mostly composed of calcium carbonate, is the result of softening hard water for distribution as drinking water. A large city such as Des Moines, Iowa, produces about 30,700 tons of lime sludge (dry weight basis) annually (Jones et al., 2005). Eight Iowa cities representing, according to the United States (U.S.) Census Bureau, 23% of the state’s population of 3 million, were surveyed. They estimated that they collectively produce 64,470 tons of lime sludge (dry weight basis) per year, and they currently have 371,800 tons (dry weight basis) stockpiled. Recently, the Iowa Department of Natural Resources directed those cities using lime softening in drinking water treatment to stop digging new lagoons to dispose of lime sludge. Five Iowa cities with stockpiles of lime sludge funded this research. The research goal was to find useful and economical alternatives for the use of lime sludge. Feasibility studies tested the efficacy of using lime sludge in cement production, power plant SOx treatment, dust control on gravel roads, wastewater neutralization, and in-fill materials for road construction. Applications using lime sludge in cement production, power plant SOx treatment, and wastewater neutralization, and as a fill material for road construction showed positive results, but the dust control application did not. Since the fill material application showed the most promise in accomplishing the project’s goal within the time limits of this research project, it was chosen for further investigation. Lime sludge is classified as inorganic silt with low plasticity. Since it only has an unconfined compressive strength of approximately 110 kPa, mixtures with fly ash and cement were developed to obtain higher strengths. When fly ash was added at a rate of 50% of the dry weight of the lime sludge, the unconfined strength increased to 1600 kPa. Further, friction angles and California Bearing Ratios were higher than those published for soils of the same classification. However, the mixtures do not perform well in durability tests. The mixtures tested did not survive 12 cycles of freezing and thawing and wetting and drying without excessive mass and volume loss. Thus, these mixtures must be placed at depths below the freezing line in the soil profile. The results demonstrated that chemically stabilized lime sludge is able to contribute bulk volume to embankments in road construction projects.

Rehabilitation of Concrete Pavements Utilizing Rubblization and Crack and Seat Methods (Phase II): Performance Evaluation of Rubblized Pavements in Iowa, TR-550, 2008

This Phase II follow-up study of IHRB Project TR-473 focused on the performance evaluation of rubblized pavements in Iowa. The primary objective of this study was to evaluate the structural condition of existing rubblized concrete pavements across Iowa through Falling Weight Deflectometer (FWD) tests, Dynamic Cone Penetrometer (DCP) tests, visual pavement distress surveys, etc. Through backcalculation of FWD deflection data using the Iowa State University's advanced layer moduli backcalculation program, the rubblized layer moduli were determined for various projects and compared with each other for correlating with the long-term pavement performance. The AASHTO structural layer coefficient for rubblized layer was also calculated using the rubblized layer moduli. To validate the mechanistic-empirical (M-E) hot mix asphalt (HMA) overlay thickness design procedure developed during the Phase I study, the actual HMA overlay thicknesses from the rubblization projects were compared with the predicted thicknesses obtained from the design software. The results of this study show that rubblization is a valid option to use in Iowa in the rehabilitation of portland cement concrete pavements provided the foundation is strong enough to support construction operations during the rubblization process. The M-E structural design methodology developed during Phase I can estimate the HMA overlay thickness reasonably well to achieve long-lasting performance of HMA pavements. The rehabilitation strategy is recommended for continued use in Iowa under those conditions conducive for rubblization.

Performance Evaluation of Concrete Pavement Granular Subbase - Pavement Surface Condition Evaluation, TR-554, 2008

This research project covered a wide range of activities that allowed researchers to understand the relationship between stability, pavement distress, and recycled portland cement concrete (RPCC) subbase aggregate materials. Detailed laboratory and field tests, including pavement distress surveys, were conducted at 26 sites in Iowa. Findings show that specific gravities of RPCC are lower than those of crushed limestone. RPCC aggregate material varies from poorly or well-graded sand to gravel. A modified Micro-Deval test procedure showed that abrasion losses of virgin aggregate materials were within the maximum Micro-Deval abrasion loss of 30% recommended by ASTM D6028-06. Micro-Deval abrasion loss of RPCC aggregate materials, however, was much higher than that of virgin materials and exceeded 30% loss. Modulus of elasticity of RPCC subbase materials is high but variable. RPCC subbase layers normally have low permeability. The pavement surfaces for both virgin and RPCC subbase across Iowa were evaluated to fulfill the objectives of this study related to field evaluation. Visual distress surveys were conducted to gather the detailed current pavement condition information including the type, extent, and severity of the pavement distresses. The historical pavement condition information for the surveyed field sections was extracted from the Iowa DOT's Pavement Management Information System (PMIS). The current surface condition of existing field pavements with RPCC subbase was compared with the virgin aggregate subbase sections using two different approaches. The changes in pavement condition indices (PCI and IRI) with time for both types of pavements (subbases) were compared.

Crack Development in Ternary Mix Concrete Utilizing Various Saw Depths, TR-587, 2009

Early entry sawing applies sawing earlier and more shallowly than conventional sawing and is believed to increase sawing productivity and reduce the cost of the joint sawing operations. However, some early entry sawing joints (transverse joints) in Iowa were found to experience delayed cracking, sometimes up to 30 days. A concern is whether early entry sawing can lead to late-age random cracking. The present study investigated the effects of different sawing methods on random cracking in portland cement concrete (PCC) pavements. The approach was to assess the cracking potential at sawing joints by measuring the strain development of the concrete at the joints using concrete embedment strain gages. Ten joints were made with the early entry sawing method to a depth of 1.5 in., and two strain gages were installed in each of the joints. Another ten joints were made with the conventional sawing method, five of which were sawed to a depth of one-third of the pavement thickness (3.3 in.), and the other five of which were sawed to a depth of one-quarter of the pavement thickness (2.5 in.). One strain gage was installed in each joint made using conventional sawing. In total, 30 strain gages were installed in 20 joints. The results from the present study indicate that all 30 joints cracked within 25 days after paving, though most joints made using early entry sawing cracked later than the joints made using conventional sawing. No random cracking was observed in the early entry sawing test sections two months after construction. Additionally, it was found that the strain gages used were capable of monitoring the deformations at the joints. The joint crack times (or crack initiation time) measured by the strain gages were generally consistent with the visual observations.

Field Evaluation of Alternative Load Transfer Device Locations in Low Traffic Volume Pavements, TR-420, 2003

In jointed portland cement concrete pavements, dowel bars are typically used to transfer loads between adjacent slabs. A common practice is for designers to place dowel bars at a certain, consistent spacing such that a sufficient number of dowels are available to effectively transfer anticipated loads. In many cases, however, the standards developed today for new highway construction simply do not reflect the design needs of low traffic volume, rural roads. The objective of this research was to evaluate the impact of the number of dowel bars and dowel location on joint performance and ultimately on pavement performance. For this research, test sections were designed, constructed, and tested in actual field service pavement. Test sections were developed to include areas with load transfer assemblies having three and four dowels in the outer wheel path only, areas with no joint reinforcement whatsoever, and full lane dowel basket assemblies as the control. Two adjacent paving projects provided both rural and urban settings and differing base materials. This report documents the approach to implementing the study and provides discussion and suggestions based on the results of the research. The research results indicate that the use of single three or four dowel basket assemblies in the outer wheel path is acceptable for use in low truck volume roads. In the case of roadways with relatively stiff bases such as asphalt treated or stabilized bases, the use of the three dowel bar pattern in the outside wheel path is expected to provide adequate performance over the design life of the pavement. In the case of untreated or granular bases, the results indicate that the use of the three or four dowel bar basket in both wheel paths provides the best long-term solution to load transfer and faulting measurements.

Evaluation of High-Slump Concrete for Bridge Deck Overlays, TR-427, 2005

The Iowa Method for bridge deck overlays has been very successful in Iowa since its adoption in the 1970s. This method involves removal of deteriorated portions of a bridge deck followed by placement of a layer of dense (Type O) Portland Cement Concrete (PCC). The challenge encountered with this type of bridge deck overlay is that the PCC must be mixed on-site, brought to the placement area and placed with specialized equipment. This adds considerably to the cost and limits contractor selection, because not all contractors have the capability or equipment required. If it is possible for a ready-mix supplier to manufacture and deliver a dense PCC to the grade, then any competent bridge deck contractor would be able to complete the job. However, Type O concrete mixes are very stiff and generally cannot be transported and placed with ready-mix type trucks. This is where a “super-plasticizer” comes in to use. Addition of this admixture provides a substantial increase in the workability of the concrete – to the extent that it can be delivered to the site and placed on the deck directly out of a ready-mix truck. The objective of this research was to determine the feasibility of placing a deck overly of this type on county bridges within the limits of county budgets and workforce/contractor availability.

Determination and Evaluation of Alternate Methods for Managing and Controlling Highway-Related Dust, TR-449, 2002

Road dust is caused by wind entraining fine material from the roadway surface and the main source of Iowa road dust is attrition of carbonate rock used as aggregate. The mechanisms of dust suppression can be considered as two processes: increasing particle size of the surface fines by agglomeration and inhibiting degradation of the coarse material. Agglomeration may occur by capillary tension in the pore water, surfactants that increase bonding between clay particles, and cements that bind the mineral matter together. Hygroscopic dust suppressants such as calcium chloride have short durations of effectiveness because capillary tension is the primary agglomeration mechanism. Somewhat more permanent methods of agglomeration result from chemicals that cement smaller particles into a mat or larger particles. The cements include lignosulfonates, resins, and asphalt products. The duration of the cements depend on their solubility and the climate. The only dust palliative that decreases aggregate degradation is shredded shingles that act as cushions between aggregate particles. It is likely that synthetic polymers also provide some protection against coarse aggregate attrition. Calcium chloride and lignosulfonates are widely used in Iowa. Both palliatives have a useful duration of about 6 months. Calcium chloride is effective with surface soils of moderate fine content and plasticity whereas lignin works best with materials that have high fine content and high plasticity indices. Bentonite appears to be effective for up to two years and works well with surface materials having low fines and plasticity and works well with limestone aggregate. Selection of appropriate dust suppressants should be based on characterization of the road surface material. Estimation of dosage rates for potential palliatives can be based on data from this report, from technical reports, information from reliable vendors, or laboratory screening tests. The selection should include economic analysis of construction and maintenance costs. The effectiveness of the treatment should be evaluated by any of the field performance measuring techniques discussed in this report. Novel dust control agents that need research for potential application in Iowa include; acidulated soybean oil (soapstock), soybean oil, ground up asphalt shingles, and foamed asphalt. New laboratory evaluation protocols to screen additives for potential effectiveness and determine dosage are needed. A modification of ASTM D 560 to estimate the freeze-thaw and wet-dry durability of Portland cement stabilized soils would be a starting point for improved laboratory testing of dust palliatives.

Evaluation of Unbonded Ultrathin Whitetopping of Brick Streets, TR-466, 2006

Many cities in Iowa have retained the original brick street surfaces in downtown areas and in older residential areas as the base for modern driving surfaces. The original brick surfaces were not built to handle current and future traffic loadings. In recent years, these surfaces have tended to shift and become uneven, creating problems with safety. Asphaltic concrete overlays have been the typical rehabilitation technique in these situations. This has proven to be a successful rehabilitation technique in some cases; in other cases, the combination of movement of the brick and flexibility of the asphalt has proven to accentuate the original problems. Most of the existing literature on rehabilitation of brick streets shows the use of asphaltic concrete. Other rehabilitation methods include reconstruction of the brick surface and strengthening of the surface by placing asphaltic concrete or portland cement concrete, along with sand, underneath the brick layers. To date, little if anything has been done in the area of using portland cement concrete as an overlay of the brick surfaces. This final report documents the planning, construction, and performance of unbonded ultrathin whitetopping rehabilitation of a brick street in Oskaloosa, Iowa, in 2001. It also reports on a similar project in Des Moines that was constructed two years later in 2003.

Preformed Phoenix Ethylene Propylene Diene Monomer (EPDM) Compression Joint Seals, MLR-93-02, 1999

There is an ongoing drive towards improvements and achieving success in effective and long term sealing of portland cement concrete pavement contraction joints. A variety of joint sealing products and procedures have been applied in Iowa in search of improvements in seal performance. Hot poured rubberized asphalt products were mainly used for sealing all joints in earlier years for highways. In the 1980s, silicone sealant products were becoming popular, especially for the major highways. As a high level of sealant performance was not achieved from silicones in Iowa conditions, other sealing products were tried. Preformed neoprene compression seals are being tried as a substitution for silicone sealants. Due to high costs of materials and installation with neoprene seals, the search for improvements through other joint sealing products and procedures continued. An agreement was made with Phoenix, North America, Inc., to provide and install preformed Ethylene Propylene Diene Monomer (EPDM) compression joint seals. The research site was a 600 ft (183 m) test section of northbound I-29 in Pottawattamie County, Iowa. Seal installation was done August 20, 1992. Seal performance has been good over the past seven years and the seals are still showing no significant signs of decreasing performance.

Carbonate Rock Pore Size Distribution Determination through Iowa Pore Index Testing, MLR-15-01, 2015

The Iowa Pore Index (IPI) measures the pore system of carbonate (limestone and dolomite) rocks using pressurized water to infiltrate the pore system. This technique provides quantitative results for the primary and capillary (secondary) pores in carbonate rocks. These results are used in conjunction with chemical and mineralogical test results to calculate a quality number, which is used as a predictor of aggregate performance in Portland cement concrete (PCC) leading to the durability classification of the aggregate. This study had two main objectives: to determine the effect different aggregate size has on IPI test results and to establish the precision of IPI test and test apparatus. It was found that smaller aggregate size fractions could be correlated to the standard 1/2”-3/4” size sample. Generally, a particle size decrease was accompanied by a slight decrease in IPI values. The IPI testing also showed fairly good agreement of the secondary pore index number between the 1/2”-3/4”and the 3/8”-1/2” fraction. The #4-3/8” showed a greater difference of the secondary number from the 1/2”-3/4” fraction. The precision of the IPI test was established as a standard deviation (Sr) of 2.85 (Primary) and 0.87 (Secondary) with a repeatability limit (%r) of 8.5% and 14.9% for the primary and secondary values, respectively.

Mix Design Development for Pervious Concrete in Cold Weather Climates

Portland cement pervious concrete (PCPC) is being used more frequently due to its benefits in reducing the quantity of runoff water,improving water quality, enhancing pavement skid resistance during storm events by rapid drainage of water, and reducing pavement noise. In the United States, PCPC typically has high porosity and low strength, which has resulted in the limited use of pervious concrete, especially in hard wet freeze environments (e.g., the Midwestern and Northeastern United States and other parts of the world).Improving the strength and freeze-thaw durability of pervious concrete will allow an increase in its use in these regions. The objective of this research is to develop a PCPC mix that not only has sufficient porosity for stormwater infiltration, but also desirable strength and freeze-thaw durability. In this research, concrete mixes were designed with various sizes and types of aggregates, binder contents, and admixture amounts. The engineering properties of the aggregates were evaluated. Additionally, the porosity, permeability, strength, and freeze-thaw durability of each of these mixes was measured. Results indicate that PCPC made with single-sized aggregate has high permeability but not adequate strength. Adding a small percent of sand to the mix improves its strength and freeze-thaw resistance, but lowers its permeability. Although adding sand and latex improved the strength of the mix when compared with single-sized mixes, the strength of mixes where only sand was added were higher. The freeze-thaw resistance of PCPC mixes with a small percentage of sand also showed 2% mass loss after 300 cycles of freeze-thaw. The preliminary results of the effects of compaction energy on PCPC properties show that compaction energy significantly affects the freeze-thaw durability of PCPC and, to a lesser extent, reduces compressive strength and split strength and increases permeability.

Comparison of Roadway Roughness Derived from LIDAR and SFM 3D Point Clouds, HR-3001, 2015

This report describes a short-term study undertaken to investigate the potential for using dense three-dimensional (3D) point clouds generated from light detection and ranging (LIDAR) and photogrammetry to assess roadway roughness. Spatially continuous roughness maps have potential for the identification of localized roughness features, which would be a significant improvement over traditional profiling methods. This report specifically illustrates the use of terrestrial laser scanning (TLS) and photogrammetry using a process known as structure from motion (SFM) to acquire point clouds and illustrates the use of these point clouds in evaluating road roughness. Five roadway sections were chosen for scanning and testing: three gravel road sections, one portland cement concrete (PCC) section, and one asphalt concrete (AC) section. To compare clouds obtained from terrestrial laser scanning and photogrammetry, the coordinates of the clouds for the same section on the same date were matched using open source computer code. The research indicates that the technologies described are very promising for evaluating road roughness. The major advantage of both technologies is the large amount of data collected, which allows the evaluation of the full surface. Additional research is needed to further develop the use of dense 3D point clouds for roadway assessment.

Investigation into Freezing-Thawing Durability of Low-Permeability Concrete with and without Air Entraining Agent, 2009

The aim of the present study is to investigate the effect of low-permeability concrete, made with reduced water‐to‐binder ratios (w/b) and/or supplementary cementitious materials (SCMs), on the need for air entrainment to achieve freezing‐thawing (F‐T) durability. In the present study, concrete mixes were made with different types of cement (Types I and IP), with or without fly ash replacement (15%), with different water‐to‐binder ratios (w/b =0.25, 0.35, 0.45 and 0.55), and with or without air entraining agent (AEA). All concrete mixtures were controlled to have a similar slump by using different dosages of superplasticizer. The rapid chloride permeability and F-T durability of the concrete samples were determined according to ASTM C1202 and ASTM C666A, respectively. The air void structure of the concrete was studied using the Air Void Analyzer, RapidAir, and porosity tests (ASTM C642). In addition, the general concrete properties, such as slump, air content, unit weight, and 28‐day compressive strength, were evaluated. The results indicate that all concrete mixes with proper air entrainment (ASTM C231 air content ≥ 6%) showed good F‐T resistance (durability factor ≥85%). All concrete mixes without AEA showed poor F‐T resistance (durability factor < 40%), except for one mix that had very low permeability and high strength. This was the concrete made with Type IP cement and with a w/b of 0.25, which had a permeability of 520 coulombs and a compressive strength of 12,760 psi (88 MPa). There were clear relationships between the F‐T durability and hardened concrete properties of non–air entrained concrete. However, such relationships did not exist in concrete with AEA. For concrete with AEA, good F‐T durability was associated with an air void spacing factor ≤ 0.28 mm (by AVA) or ≤ 0.22 mm (by RapidAir).

An Estimate of the Cost to Resurface Pavements and Bridges Damaged by Studded Tires, 1972

This report contains an estimate of the cost of highway resurfacing necessitated by damage from studded tires. The total is $95,620,000 for the twenty-five years from 1971 to 1996. This total includes $51,937,000 to resurface pavements and bridges on Interstate routes and $43,683,000 for other Primary highways. The estimate for Interstate routes includes those sections now open to traffic and those planned for completion by November 1974. The estimate for other Primary routes includes rural and municipal sections open to traffic as of November 1970. The estimate was prepared by computing the cost of expected pavement and bridge resurfacing costs for the twenty-five year period assuming continued use of studded tires, then subtracting from this the expected resurfacing ) cost for the same period assuming that the use of' studded tires is prohibited. The total figure, $95,620,000, should be regarded as a conservative estimate of the cost which may be avoided by prohibiting the use of studded tires in Iowa. The conservative nature of the estimate may be demonstrated by the following examples of the guidelines used iri its preparation. 1. Only mainline pavements were included in the cost estimate for the Interstate routes. The connecting loops, exit ramps and entrance ramps at Interstate interchanges contain many additional miles of pavement subject to wear by studded tires. This pavement was omitted from the estimate because reliable ' information about the rate of pavement wear at such locations is not available. As a result, the Interstate resurfacing costs are underestimated. 2. Several other costs were also omitted from the estimate because of a lack of sufficient information. These include the cost of repairing damage caused by studded tires to city streets other than those designated as Primary routes, the damage to pavements and bridges on the more-heavily travelled Secondary roads, and the damage to pavement traffic markings on all highway systems. Experience indicates that portland cement concrete pavements in Iowa have a normal service life of twenty-five years before resurfacing becomes necessary. The service life for asphalt pavements is thirteen years. In making this cost estimate, the need for resurfacing was attributed to wear from studded tires only when the normal service life of the pavement was shortened by that wear. Consequently, this cost estimate does not account for the reduced safety and convenience to Iowa motorists during the time when pavement wear caused by studded tires is significant but less than the critical amount.

Cracking and Seating PCC Pavement Prior to Resurfacing, HR-527, 1986

Construction of an excellent network of primary highways across the State of Iowa has essentially been completed. The major task facing the Iowa Department of Transportation today is the maintenance and rehabilitation of that network. The most commonly utilized rehabilitation practice is asphalt concrete resurfacing. This practice will normally provide a good driving surface for at least 10 additional years. The major problem with asphalt concrete resurfacing is the reflection cracking from underlying cracks and joints in the portland cement concrete (PCC) pavement. Deterioration and spaling occur at these reflection cracks and are the limiting factor of the-effective life of the asphalt concrete resurfacing.