Evaluation of Dense Bridge Floor Concrete using Superplasticizer, HR-192, 1977

Much effort is being expended by various state, federal, and private organizations relative to the protection and preservation of concrete bridge floors. The generally recognized culprit is the chloride ion, from the deicing salt, reaching the reinforcing steel, and along with water and oxygen, causing corrosion. The corrosion process exerts pressure which eventually causes cracks and spalls in the bridge floor. The reinforcing· has been treated and coated, various types of "waterproof" membranes have been placed on the deck surface, decks have been surfaced with dense and modified concretes, decks have been electrically protected, and attempts to internally seal the concrete have been made. As of yet, no one method has been proven and accepted by the various government agencies as being the "best" when considering the initial cost, application effort, length and effectiveness of protection, etc.

Thin Bonded Portland Cement Concrete Overlay, HR-520, 1990

A four and one-half inch thick, bonded portland cement concrete (PCC) overlay and integral widening were used to rehabilitate a 4.5 mile section of Iowa route 141 from US 169 to Iowa 210 in Dallas County. There was a substantial amount of cracking in the old 20 feet wide PCC pavement. Most of the widening, which was tied to the original slab by dowel bars, was placed as a four feet wide section on one side. Coring has shown that the overlay is well bonded and testing with the Delamtect has shown less than 1% debonding. Midpanel transverse cracks in the old pavement have reflected through the overlay (as expected). Some new transverse cracking has occurred. This cracking has not caused any significant problems. In general, the overlay is performing quite well.

Iowa D.O.T's Experience with Recycling Portland Cement Pavement and Asphalt Cement Pavement, MLR-77-4, 1977

This report provides details of IADOT's experience removing and crushing asphaltic concrete and portland cement concrete for recycling. The recycled material was used on interstate highways for the subbase and shoulders. The major problem IADOT encountered on this project was the removal of reinforcing steel from the broken concrete. The contractor used hydraulic powered shears to clip off all protruding steel during the removal and loading of the concrete on the grade. This project took place in 1977.

Deicing Salt Corrosion with and without Inhibitors, MLR-87-8, 1989

Chloride ion penetration through concrete to reinforcing steel is causing the premature deterioration of numerous bridge decks in Iowa. The purpose of the research reported in this paper was to determine whether any of several additives or alternative deicing chemicals could inhibit corrosion of reinforcing steel. The deicers tested were calcium magnesium acetate (CMA), CMA plus NaCl (NaCl: sodium chloride), Quicksalt plus PCI, and CG-90, a polyphosphate solution being developed by Cargill. Two tests were established. First, steel coupons were placed in a 15% solution of a deicer and distilled water to determine which alternative deicer would cause the least amount of corrosion in solution. The coupons were weighed periodically to determine each coupon's weight loss from corrosion. The second test involved ponding a 15% solution of each material on reinforced concrete blocks. Weekly copper-copper sulfate electrical half-cell (CSE) potential readings were taken on each block to determine whether corrosive activity was occurring at the steel surface. When the ponding research was concluded, concrete samples were taken from one of the three blocks ponded with each deicer. The samples were used to determine the chloride ion content at the level of the steel. Results show that all the deicers were less corrosive than NaCl. Only pure CMA, however, significantly inhibited the corrosion of steel embedded in concrete.

Low Permeability of Concrete for Bridge Deck Overlay, MLR-89-1, 1993

The penetration of chloride ions from deicing salts into the portland cement concrete of bridge decks can cause corrosion and serious damage to the reinforcing steel. Concrete properties which prevent chloride penetration into the bridge deck and provide a good structural and economic wearing surface are desirable. A variety of mix designs have been tried in the past in search of improved performance and lower costs for bridge deck overlay concrete. A group of mixes with various designs have been tested in this project and results are being compared to determine which concrete mix appears to be the most cost effective and resistant to chloride penetration for bridge deck overlay use.

Impact of Deck Cracking on Durability, TR-405, 2000

Concrete bridge decks subjected to corrosive environment because of the application of de-icing chemical could deteriorate at a rapid rate. In an effort to minimize corrosion of the reinforcement and the corresponding delaminations and spalls, the Iowa Department of Transportation started using epoxy-coated rebars (ECR) in the top mat of reinforcing around 1976 and in both mats 10 years later. The overall objective of this research was to determine the impact of deck cracking on durability and estimate the remaining functional service life of a bridge deck. This was accomplished by conducting a literature review, visually inspecting several bridge decks, collecting and sampling test cores from cracked and uncracked areas of bridge decks, determining the extent to which epoxy-coated rebars deteriorate at the site of cracks, and evaluating the impact of cracking on service life.

A Study of Portland Cement Maintenance Mix and Set Accelerators, R-249, 1970

The large volume of traffic on the interstate system makes it difficult to make pavement repairs. The maintenance crew needs 4-5 hours to break out the concrete to be replaced and prepare the hole for placing new concrete. Because of this it is usually noon before the patch can be placed. Since it is desirable to remove the barricades before dark there are only 7-8 hours for the concrete to reach the required strength. There exists a need for a concrete that can reach the necessary strength (modulus of rupture = 500 psi) in 7-8 hours. The purpose of this study is to determine if type III cement and/or an accelerator can be used in an M-4 mix to yield a fast setting patch with very little shrinkage. It is recognized that calcium chloride is a corrosive material and may therefore have detrimental effects upon the reinforcing steel. The study of these effects, however, is beyond the scope of this investigation.

Protection of Structural Concrete Substructures, HR-220, Progress Report, 1984

The corrosion of reinforcing steel within concrete has always been a problem in construction of bridge decks. With low slump concrete and epoxy rebar, progress has been made in controlling the corrosion. There is concern, however, that the chloride also attacks the substructures, specifically the pier columns. They are subject to chloride attack by chemical deicers in the drainage from the bridge deck. Piers supporting grade separation bridges are also subject to chlorides contained in the direct splash from the lower level traffic. In this project, a field evaluation was conducted to evaluate the effectiveness of commercially available products in preventing chloride intrusion.

Bridge Deck Waterproofing Membrane Study, R-262, 1974

One of the main problems of bridge maintenance in Iowa is the spalling and scaling of the decks. This problem stems from the continued use of deicing salts during the winter months. Since bridges will frost or freeze more often than roadways, the use of deicing salts on bridges is more frequent. The salt which is spread onto the bridge dissolves in water and permeates into the concrete deck. When the salt reaches the depth of the reinforcing steel and the concentration at that depth reaches the threshold concentration for corrosion (1.5 lbs./yd. 3 ), the steel will begin to oxidize. The oxidizing steel must then expand within the concrete. This expansion eventually forces undersurface fractures and spalls in the concrete. The spalling increases maintenance problems on bridges and in some cases has forced resurfacing after only a few years of service. There are two possible solutions to this problem. One solution is discontinuing the use of salts as the deicing agent on bridges and the other is preventing the salt from reaching or attacking the reinforcing steel. This report deals with one method which stops the salt from reaching the reinforcing steel. The method utilizes a waterproof membrane on the surface of a bridge deck. The waterproof membrane stops the water-salt solution from entering the concrete so the salt cannot reach the reinforcing steel.

A Further Evaluation of Concrete Bridge Deck Surfacing in Iowa, MLR-79-1, 1979

The Iowa Department of Transportation has overlaid 446 bridge decks with low slump dense concrete from 1964 through October 1978. The overall performance of these decks has been satisfactory. Nineteen bridges that were resurfaced with either low slump dense concrete (LSDC) or latex-modified concrete were analyzed for chloride content, electrical corrosion potential, delaminations or debonding, and deck surface condition. The resurfacing ages of these bridges range from 5 to 13 years. None of the bridges showed any evidence of surface distress and the chloride penetration into the resurfacing concrete is relatively low. There are delaminations in the original decks below the resurfacing on the majority of bridges examined. The delaminations are concluded to be caused by either (A) reinforcing steel corrosion, (B) not removing all delaminated concrete prior to placing the resurfacing concrete, or (C) creating an incipient fracture in the top surf ace of the original deck through the use of scarification equipment. The active corrosion of the reinforcing steel is predominately in the gutter line on the majority of bridges evaluated. Recommendations for future deck repairs include removal of concrete to the top layer of reinforcing steel in areas where an electrical corrosion potential of -0.35V or more is detected, providing more positive methods of locating delaminated concrete, and treating the curb and gutter line to reduce the potential damage from salt water.

RFID Tags for Detecting Concrete Degradation in Bridge Decks, RB08-011, 2013

Steel reinforcing bar (rebar) corrosion due to chlorine ingress is the primary degradation mechanism for bridge decks. In areas where rock salt is used as a de-icing agent, salt water seeps into the concrete through cracks, causing corrosion of the rebar and potentially leading to catastrophic failure if not repaired. This project explores the use of radio frequency identification (RFID) tags as low-cost corrosion sensors. RFID tags, when embedded in concrete, will fail due to corrosion in the same manner as rebar after prolonged exposure to salt water. In addition, the presence of salt water interferes with the ability to detect the tags, providing a secondary mechanism by which this method can work. During this project, a fieldable RFID equipment setup was constructed and tested. In addition to a number of laboratory experiments to validate the underlying principles, RFID tags were embedded and tested in several actual bridge decks. Two major challenges were addressed in this project: issues associated with tags not functioning due to being in close proximity to rebar and issues associated with portland concrete coming in direct contact with the tags causing a detuning effect and preventing the tags from operating properly. Both issues were investigated thoroughly. The first issue was determined to be a problem only if the tags are placed in close proximity to rebar. The second issue was resolved by encapsulating the tag. Two materials, polyurethane spray foam and extruded polystyrene, were identified as providing good performance after testing, both in the lab and in the field.

Detection of Steel Corrosion in Bridge Decks and Reinforced Concrete Pavement, HR-156, 1977

The Iowa Department of Transportation initiated this research to evaluate the reliability, benefit and application of the corrosion detection device. Through field testing prior to repair projects and inspection at the time of repair, the device was shown to be reliable. With the reliability established, twelve additional devices were purchased so that this evaluation procedure could be used routinely on all repair projects. The corrosion detection device was established as a means for determining concrete removal for repair. Removal of the concrete down to the top reinforcing steel is required for all areas exhibiting electrical potentials greater than 0.45 Volt. It was determined that the corrosion detection device was not applicable to membrane testing. The corrosion detection device has been used to evaluate corrosion of reinforcing steel in continuously reinforced concrete pavement.

Prevention of Reflection Cracking in Asphalt Overlays with Structofors, Petromate, and Cerex, HR-158, 1977

This report presents construction methods and results using three reinforcing fabrics to prevent reflection cracking in an asphalt overlay. The original highway in the rural area was Portland Cement Concrete 20 feet wide. It was widened by adding 2 feet of asphaltic concrete 10 inches deep on each side prior to resurfacing. Data are presented for the widening joint and transverse cracks in the rural area and for the random cracking in the urban area.

Cathodic Protection for a Continuous Box Girder Bridge Deck, HR-553, 1993

Bridge deck deterioration due to corrosive effect of deicers on reinforcing steel is a major problem facing many agencies. Cathodic protection is one method used to prevent reinforcing steel corrosion. The application of a direct current to the embedded reinforcing steel and a sacrificial anode protects the steel from corrosion. This 1992 project involved placing an Elgard Titanium Anode Mesh Cathodic Protection System on a bridge deck. The anode was fastened to the deck after the Class A repair-work and the overlay was placed using the Iowa Low Slump Dense Concrete System. The system was set up initially at 1 mA/sq ft.

Establishing Load Transfer in Existing Jointed Concrete Pavements, HR-1041, 1985

In this paper are described the results of a research project that had the objective of developing construction procedures for restoring load transfer in existing jointed concrete pavements and of evaluating the effectiveness of the restoration methods. A total of 28 test sections with various load transfer devices were placed. The devices include split pipe, figure eight, vee, double vee, and dowel bars. Patching materials used on the project included three types of fast-setting grouts, three brands of polymer concrete, and plain portland cement concrete. The number and spacing of the devices and dowel bars were also variables in the project. Dowel bars and double vee devices were used on the major portion of the project. Performance evaluations were based on deflection tests conducted with a 20,000-lb axle load. Horizontal joint movement measurements and visual observations were also made. The short-term performance data indicate good results with the dowel bar installations regardless of patching materials. The sections with split pipe, figure eight, and vee devices failed in bond during the first winter cycle. The results with the double vee sections indicate the importance of the patching material to the success or failure of the load transfer system: some sections are performing well and other sections are performing poorly with double vee devices. Horizontal joint movement measurements indicate that neither the dowel bars nor the double vee devices are restricting joint movement.