Field Evaluation of Quality Management Concrete, MLR-97-3, 1998

Quality management concrete allows the contractor to develop the mix design for the portland cement concrete. This research was initiated to gain knowledge about contractor mix designs. An experiment was done to determine the variation in cylinders, beams, and cores that could be used to test the strength of the contractor's mix. In addition, the contractor's cylinder strengths and gradations were analyzed for statistical stability and process capability. This research supports the following conclusions: (1) The mold type used to cast the concrete cylinders had an effect on the compressive strength of the concrete. The 4.5-in. by 9-in. (11.43-cm by 22.86-cm) cylinders had lower strength at a 95% confidence interval than the 4-in. by 8-in. (10.16-cm by 20.32-cm) and 6-in. by 12-in. (15.24-cm by 30.48-cm) cylinders. (2) The low vibration consolidation effort had the lowest strength of the three consolidation efforts. In particular, an interaction occurred between the low vibration effort and the 4.5-in. by 9-in. (11.43-cm by 22.86-cm) mold. This interaction produced very low compressive strengths when compared with the other consolidation efforts. (3) A correlation of 0.64 R-squared was found between the 28 day cylinder and 28 day compressive strengths. (4) The compressive strength results of the process control testing were not in statistical control. The aggregate gradations were mostly in statistical control. The gradation process was capable of meeting specification requirements. However, many of the sieves were off target. (5) The fineness modulus of the aggregate gradations did not correlate well with the strength of the concrete. However, this is not surprising considering that the gradation tests and the strength tests did not represent the same material. In addition, the concrete still has many other variables that will affect its strength that were not controlled.

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.

Blanket Curing to Promote Early Strength Concrete, MLR-87-7, 1989

Fast Track concrete has proven to be successful in obtaining high early strengths. This benefit does not come without cost. Special Type III cement and insulating blankets to accelerate the cure add to its expense when compared to conventional paving. This research was intended to determine the benefit derived from the use of insulating blankets to accelerate strength gain in three concrete mixes using Type I cement. The goal was to determine mixes and curing procedures that would result in a range of opening times. This determination would allow the most economical design for a particular project by tailoring it to a specific time restraint. Three mixes of various cement content were tested in the field. Flexural beams were cast for each mix and tested at various ages. Two test sections were placed for each mix, one section being cured with the addition of insulating blankets and the other being cured with only conventional curing compound. Iowa Department of Transportation specifications require 500 psi flexural strength before a pavement can be opened to traffic. Concrete with Fast Track proportions (nominal 7 1/2 bag), Type I cement, and insulating blankets reached that strength in approximately 36 hr, a standard mix (nominal 6 1/2 bag) using the blankets in approximately 48 hr, and the Fast Track proportions with Type I cement without blankets in about 60 hr. The results showed a significant improvement in early strength gain with the use of insulating blankets.

New Method for Breaking High Strength Prestress Cable, MLR-97-6, 1997

A new method was developed for breaking high strength prestressed cable. The old method used an aluminum oxide grit packed into a special gripping jaw. The new method uses aluminum shims wrapped around the cable and then is gripped with a V-grip. The new method gives nearly 100% "good breaks" on the cable compared to approximately 10% good breaks with the old method. In addition, the new cable breaking method gives higher ultimate tensile strengths, is more reproducible, is quicker, cleaner and easier on equipment.

Special Cements for Fast Track Concrete, MLR-87-4, 1988

Two specialty cements are currently being marketed as a way to achieve portland cement concrete pavement opening strengths at less than 12 hours after placement. The cements are Pyrament from Pyrament/Lone Star Industries of Houston, Texas and Ideal Regulated-Set (RS) Portland Cement from Ideal Cement Company of Saratoga, Arkansas. The objective of the study was to evaluate the strength gain and durability of concrete produced with Pyrament and Ideal RS cement as Fast Track concrete. Mixes with 610 lb/cu yd (362 kg/cu m) cement were made and tested. Both Pyrament and Ideal RS are capable of producing pavement opening times less than 12 hours. Recent changes to Ideal RS cement have produced concrete flexural strengths of 550 psi (3792 kPa) at 4 hours in Iowa tests. Freeze/thaw durability of the concrete was not adversely affected by using either cement.

Evaluation of Concrete Patching Mixes and Opening Time Using the Maturity Concept, MLR-93-7, 1993

This report summarizes the findings of a research which was intended to evaluate the concrete strength and opening time for the full depth patching projects in Iowa under cold weather and whether or not cold water could be allowed in the mix. This research was performed both in the laboratory and in the field. The results indicated that with the present specification the concrete strength after five hours for two-lane patches which requires hot water and calcium chloride is about 1,600 psi. Hence, if a higher strength is desired, a longer curing time is required. Hot water will have to be used and water reducer is not recommended for two-lane patches. On the other hand, the concrete strength for multi-lane patches with either hot or cold water approaches 4,000 psi in less than 24 hours. There was only a slight difference in compressive strengths between the 24-hour and 36-hours curing times.

Evaluation of Photoacoustic Spectroscopy for Quality Control of Cement, TR-409, 1998

This report discusses the feasibility of using infrared photoacoustic spectroscopy (PAS) as a viable technique that can quickly provide information on cement composition prior to use. The PAS technique is of interest because the cost is much lower than for other types of instrumentation used for mineral analysis, it requires virtually no sample preparation, and it can perform multi-component analysis in a matter of minutes. Feasibility of the technique was based on the ability of PAS to identify and quantify sulfate species and major cement matrix components. Strengths and limitations of the technique are presented.

Strength-Temperature Study of Fly Ash Concrete, MLR-84-6, 1984

Class A, B, and C concrete paving mixes were tested for compressive strength at 40°F and 73°F, both with and without fly ash substitution for 15% of the portland cement. Two Class C ashes and one Class F ash from Iowa approved sources were examined in each mix. The purpose of the study was to provide data on cool weather strength development of concrete paving mixes utilizing Iowa materials. In all cases except one, the fly ash concretes exhibited lower 7 and 28- day compressive strengths at 40°F than control mixes. The continuation of the October 15 cut-off date for the use of fly ash concrete is recommended.

An Investigation of Portland Cement Concrete Utilizing 70% Class V Aggregate and 30% Calcareous Coarse Aggregate, R-255, 1973

The main sources of coarse aggregate for secondary slip form paving in Southwest Iowa exhibit undesirable "D" cracking. "D" cracking is a discoloration of the concrete caused by fine, hairline cracks. These cracks are caused by the freezing and thawing of moisture inside the coarse aggregate. The cracks are often hour glass shaped, are parallel to each other, and occur along saw joints. The B-4, a typical secondary mix, utilizes 50% fine aggregate and 50% coarse aggregate. It has been proposed that a concrete mix with less coarse aggregate and more fine aggregate might impede this type of deterioration. The Nebraska Standard 47B Mix, a 70% fine aggregate, and 30% coarse aggregate mix, as used by Nebraska Department of Roads produces concrete with ultimate strengths in excess of 4500 psi but because of the higher cost of cement (it is a six bag per cubic yard mix) is not competitive with our present secondary mixes. The sands of Southwest Iowa generally have poorer mortar strengths than the average Iowa Sand. Class V Aggregate also found in Southwest Iowa has a coarser sand fraction, therefore it has a better mortar strength, but exhibits an acidic reaction and therefore must be·used with limestone. This illustrates the need to find a mix for use in Southwest Iowa that possesses adequate strength and satisfactory durability at a low cost. The purpose of this study is to determine a concrete mix with an acceptable cement content which will produce physical properties similar to that of our present secondary paving mixes.

Time-Temperature Strength-Reaction Product Relationships in Lime-Bentonite-Water Mixtures, HR-111, 1965

The interrelation of curing time, curing temperature, strength, and reactions in lime-bentonite-water mixtures was examined. Samples were molded at constant density and moisture content and then cured for periods of from 1 to 56 days at constant temperatures that ranged from 5C to 60C. After the appropriate curing time the samples were tested for unconfined compressive strength. The broken samples were then analyzed by x-ray diffractometer and spectrophotometer to determine the identity of the reaction products present after each curing period. It was found that the strength gain of lime-clay mixtures cured at different temperatures is due to different phases of the complex reaction, lime & clay to CSH(gel) to CSH(II) to CSH(I) to tobermorite. The farther the reaction proceeds, the higher the strength. There was also evidence of lattice substitutions in the structure of the calcium silicate hydrates at curing temperatures of 50C and higher. No consistent relationship between time, temperature, strength, and the S/A ration of reaction products existed, but in order to achieve high strengths the apparent C/S ration had to be less than two. The curing temperature had an effect on the strength developed by a given amount of reacted silica in the cured lime-clay mixture, but at a given curing temperature the cured sample that had the largest amount of reacted silica gave the highest strength. Evidence was found to indicate that during the clay reaction some calcium is indeed adsorbed onto the clay structure rather than entering into a pozzolanic reaction. Finally, it was determined that it is possible to determine the amount of silica and alumina in lime-clay reaction products by spectrophotometric analysis with sufficient accuracy for comparison purposes. The spectrophotometric analysis techniques used during the investigation were simple and were not time consuming.

Evaluation of Fly Ash in Bridge Deck Concrete, MLR-84-2, 1985

Fly ash was used in this evaluation study to replace 15% of the cement in Class D-57 structural concrete containing ASTM C494 Type B, retarding admixtures. Two Class "C" ashes and one Class "F" ash from Iowa approved sources were examined in each mix. When Class "C" ashes were used, they were substituted on the basis of 1.0 pound for each pound of cement removed. When Class "F" ash was used, it was substituted on the basis of 1.25 pounds of ash for each pound of cement removed. Compressive strengths of the retarded mixes, with and without fly ash, were determined at 7, 28 and 56 days of age. In most cases, with few exceptions, the mixes containing the fly ash exhibited higher strengths than the same concrete mix without the fly ash. The exceptions were the 7, 28, and 56 days of the mixes containing Class F ash. The freeze/thaw durability of the concrete studied was not affected by the presence of fly ash. The data obtained suggested that the present Class D-57 structural concrete mix with retarding admixtures can be modified to allow the substitution of 15% of the cement with an approved fly ash when Class III coarse aggregates are used. Setting times of the concretes were not materially changed due to the incorporation of fly ash.

New Method for Breaking High Strength Prestress Cable, MLR-97-6, 1997

A new method was developed for breaking high strength prestressed cable. The old method used an aluminum oxide grit packed into a special gripping jaw. The new method uses aluminum shims wrapped around the cable and then is gripped with a V-grip. The new method gives nearly 100% "good breaks" on the cable compared to approximately 10% good breaks with the old method. In addition, the new cable breaking method gives higher ultimate tensile strengths, is more reproducible, is quicker, cleaner and easier on equipment.

Investigation of High Performance Concrete Pavement, MLR-05-01, 2006

The Iowa DOT has been using blended cements in ternary mixes since 1999. Use of these supplementary cementitious materials gives concrete with higher strengths and much lower permeability. Use of these materials has been incorporated for use in High Performance Concrete (HPC) decks to achieve lower permeability and thus long term performance. Since we have been using these materials in paving, it would be informative to determine what concrete pavement properties are enhanced as related to high performance concrete. The air void system was excellent at a spacing factor of 0.0047 in (0.120 mm). AVA spacing factor results are much higher than the hardened air void analysis. Although only 3 samples were tested between the image analysis air content and the RapidAir457, there is pretty good agreement between those test methods. Air void analysis indicates that excessive vibration was not required to place the concrete. Vibration was well within the specification limits with an average of 6683 vpm’s with a standard deviation of 461. Overall ride of the project was very good. The average smoothness for the project was 2.1 in/mile (33.8 mm/km). The International Roughness Index (IRI) was 81 in/mi (1.29 m/km). The compressive strength was 6260 psi (43.2 MPa) at 28 days and 6830 (47.1 MPa) at 56 days. The modulus of rupture by third point loading (MOR-TPL) tested at 28 days was 660 psi (4.55 MPa). The AASHTO T277 rapid chloride permeability results at 28 days using the Virginia cure method correlate fairly well with the 56 and 90 day results with standard curing. The Virginia cure method 28 day results were 2475 coulombs and the standard cure 56 and 90 day test results were 2180 and 2118, respectively.

Evaluation of Metakaolin for HPC Deck Overlays, MLR-11-01, 2011

The use of High Performance Concrete (HPC) in Iowa has consisted of achieving slightly higher compressive strengths with an emphasis on reduced permeability. Concrete with reduced permeability has increased durability by slowing moisture and chloride ingress. Achieving reduced permeability has typically been accomplished with combinations of slag and Class C fly ash, or the use of blended cements such as locally available Type IS(20), IS(25) and Type IP(25) in conjunction with Class C fly ash. Fly ash has been used in the majority of concrete placed in Iowa since 1984 and slag has been available in Iowa since 1995. During the economic downturn in 2008, one of the cement plants that produced a Type IS(25) cement was forced to shut down, which reduced the availability of blended cements, typically used on HPC deck overlays. Recently, a source of high reactivity metakaolin has been made available. Metakaolin is produced by heating a pure kaolinite clay to 650 to 700 °C in a rotary kiln (calcining). Metakaolin is a white pozzolan that is used to produce concrete with increased strengths, reduced permeability, reduced efflorescence, and resistance to alkali silica reactivity. The W.R. Grace MK-100 metakaolin will likely be available in dissolvable bags between 25 and 50 pounds. Thus, the mix designs were based on the anticipated bag size range for field use. This research evaluated metakaolin mixes with and without Class C fly ash. Results indicated a seven percent replacement with metakaolin produced concrete with increased strengths and low permeability. When used with Class C fly ash, permeability is reduced to very low rating. Metakaolin may be used to enhance hardened concrete properties for use in high performance concrete (HPC).

Report on Fly Ash as a Soil Additive, MLR-81-03, 1981

The addition of a selected self-cementing, Class C fly ash to blow sand soils improves their compacted strength greatly as opposed to the minimal strength improvement when fly ash is mixed with loess soil. By varying the percentage of fly ash added, the resulting blow sand-fly ash mixture can function as a low strength stabilized material or as a higher strength sub-base. Low strength stabilized material can also be obtained by mixing loess soils with a selected Class C fly ash. The development of the higher strength values required for subbase materials is very dependent upon compaction delay time and moisture condition of the material. Results at this time indicate that, when compaction delays are involved, excess moisture in the material has the greatest positive effect in achieving minimum strengths. Other added retarding agents, such as borax and gypsum, have less effect.