Evaluation of Fly Ash in Portland Cement Concrete Paving in Woodbury County, Iowa, HR-201, Construction Report, 1979

The earliest overall comprehensive work on the use of fly ash in concrete was reported by Davis and Associates of the University of California in 1937. Since that time there have been numerous applications of the use and varying proportions of fly ash in portland cement concrete mixes. Fly ash is a pozzolanic powdery by-product of the coal combustion process which is recovered from flue gases and is generally associated with electric power generating plants. Environmental regulations enacted in recent years have required that fly ash be removed from the flue gases to maintain clean air standards. This has resulted in an increased volume of high quality fly ash that is considered a waste product or a by-product that can be utilized in products such as portland cement concrete. There are several sources of the high quality fly ash located in Iowa currently producing a combined total of 281,000 tons of material annually. Due to recent cement shortages and the rapidly increasing highway construction costs, the Iowa Department of Transportation has become interested in utilizing fly ash in portland cement concrete paving mixes. A preliminary review of the Iowa Department of Transportation Materials Laboratory study indicates that a substitution of fly ash for portland cement, within limits, is ·not detrimental to the overall concrete quality. Also the use of fly ash in concrete would reduce the cement consumption as well as provide a potential cost savings in areas where high quality fly ash is available without excessive transportation costs. The previously expressed concerns have shown the need for a research project to develop our knowledge of fly ash replacement in the Iowa Department of Transportation portland cement concrete paving mixes.

Recycled Portland Cement Concrete Pavement in Iowa, HR-506, 1984

In recent years, there has been an increased interest in conservation of our resources, preservation of our environment and maintaining our ecology. Recycling of materials is a procedure that will immediately contribute to all of these desirable end results. Our economy is built on private enterprise and profit incentive and in the past, with abundant inexpensive resources, there was little incentive to recycle. Shortages of materials and energy (once considered abundant) along with regulations to protect the environment have emphasized the need for recycling. These environmental conditions coupled with the loss of purchase power by inflation has generated more interest in recycling in the transportation field. The Iowa Department of Transportation (Iowa DOT) is interested in recycling portland cement concrete (pcc) pavement to: 1. Provide aggregate where high quality aggregate is no longer economically available. 2. Eliminate the need for locations to waste the large amount of pavement rubble. 3. Conserve the present aggregate sources. 4. Reduce the need for disrupting land for quarrying purposes. 5. Save fuel and energy by reducing aggregate transportation.

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.

Polymerized Asphalt Cement, HR-533, 1989

In 1986, a 0.34 mile experimental section of polymerized asphalt cement (PAC30) concrete was placed in the westbound driving lane of Interstate 80 in western Iowa. It was used in a 2" asphalt concrete inlay using 20% recycled asphalt pavement. The virgin aggregate included 41% crushed gravel, 25% crushed quartzite and 14% natural sand. The evaluation of the project was severely limited when a 1987 reconstruction project extended into the experimental section leaving only 395 feet. Rut depths under a 4-foot gage were taken for a period of two years. No significant rutting occurred in the experimental polymerized section. The frequency of transverse cracking in the polymerized AC section was the same as that of the comparative AC-20 section. The asphalt paving mixture made with polymerized AC cost 120% of the cost of the conventional mix.

Fast Track Portland Cement Concrete Pavement, HR-538, 1997

In 1987, 1.5 km (0.935 mi.) of Spruce Hill Drive in Bettendorf, Iowa was reconstructed. It is an arteriel street with commercial usage on both termini with single family residential dwellings along most of the project. A portland cement concrete (PCC) pavement design was selected, but a 14 day curing period would have been an undue hardship on the residents and commercial businesses. An Iowa DOT Class F fast track concrete was used so the roadway could be used in 7 to 10 days. The Class F concrete with fly ash was relatively sticky and exhibited early stiffening problems and substantial difficulty in obtaining the target entrained air content of 6.5%. These problems were never completely resolved on the project. Annual visual field reviews were conducted through 1996. In November 1991, severe premature distress was identified on the westbound two lanes of the full width replacement. The most deteriorated section in a sag vertical, 152 m (500 ft.) of the westbound roadway, was replaced in 1996. Premature distress has been identified on a dozen other conventional PCC Iowa pavements constructed between 1983 and 1989, so the deterioration may not be related to the fact that it was fast track pavement.

Bonded, Thin-Lift, Non-Reinforced Portland Cement Concrete Resurfacing, MLR-77-2, 1977

A research project involving 2, 3, 4, and 5 in. (5.1, 7.6, 10.2, and 12.7 cm) of bonded portland cement concrete (PCC) overlay on a 1.3 mile (2.1 km) PCC pavement was conducted in Clayton County, Iowa, during September 1977, centering on the following objectives: (1) Determine the mixing and proportioning procedures required in using a conventional, central mix proportioning plant to produce a dense PCC mixture using standard mixes with super water reducing admixtures; (2) Determine the economics, longevity and maintenance performance of a bonded, thin-lift, non-reinforced PCC resurfacing course using conventional procedures, equipment and concrete paving mixtures both with and without super water reducing admixtures; and (3) Determine if an adequate bond between the existing pavement and an overlay of thin-lift, dense, non-reinforced PCC can be obtained with only special surface cleaning and no surface removal or grinding. The conclusions are as follows: (1) Normal mixing equipment and proportioning procedures could be used using a conventional central-mix proportioning plant. This was successful when used with super water reducing admixtures. Only minor changes need be made in procedures and timing. (2) The time has been too short since the completion of the project to determine how the new pavement will perform, however, initially it appears that the method is economical and no reason is seen at this time why the life of the pavement should not be comparable to an all new pavement. (3) The initial test results show that bond strength, regardless of which method of cleaning is used, scarifying, sand blasting or water blasting, far exceed what is considered the minimum bond strength of 200 psi (1379 kPa) except where the paint stripes were intentionally left, thus showing that the paint must be removed. (4) It appears that either cement and water grout or sand, cement and water grout may be used and still obtain the required bond.

Portland Cement Concrete Utilizing Recycled Pavement, MLR-77-3, 1977

Two objectives were involved in this recycling project: To determine if the asphalt concrete surfacing from an existing roadway could be removed, the existing portland cement concrete pavement broken, removed, crushed to 1-1/2 inch minus, proportioned through a conventional central mix proportioning plant with the addition of concrete sand, and placed with a conventional slipform paver; and to determine if a two course, composite pavement, each course of different mix proportions, could be placed monolithically with conventional slipform equipment after being proportioned and mixed in a conventional central mix plant. The project was completed with no major problem. The objectives were satisfactorily met. The project was a success to the degree that the Iowa D.O.T. is proceeding with at least two projects for the 1977 construction season that will utilize the old pavement as appregate for the new pavement.

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.

Evaluation of Type I Cement Fast Track Concrete, MLR-87-6, 1988

There are projects where opening the pavement to traffic in less than the 5 to 7 days is needed, but an 8 to 12 hour opening time is not necessary. The study examined fast track concrete with Type I cement and admixtures. The variables studied were: (1) cure temperature, (2) cement brand, (3) accelerators, and (4) water reducers. A standard water reducer and curing blankets appear to be effective at producing a 24 hour to 36 hour opening strength. An accelerator and/or high range water reducer may produce opening strength in 12 to 24 hours. Calcium chloride was most effective at achieving high-early strength.

Vibration Study for Consolidation of Portland Cement Concrete, MLR-95-4, 1999

The Iowa Department of Transportation has noticed an increase in the occurrence of excessively vibrated portland cement concrete (PCC) pavements. The overconsolidation of PCC pavements can be observed in several sections of PCC highways across the state of Iowa. Also, excessive vibration is believed to be a factor in the premature deterioration of several pavements in Iowa. To address the problem of excessive vibration, a research project was conducted to document the vibratory practices of PCC slipform paving in Iowa and determine the effect of vibration on the air content of pavement. The primary factors studied were paver speed, vibrator frequency, and air content relative to the location of the vibrator. The study concluded that the Iowa Department of Transportation specification of 5000 and 8000 vibrations per minute (vpm) for slipform pavers is effective for normal paver speeds observed on the three test paving projects. Excessive vibration was clearly identified on one project where a vibrator frequency was found to be 12,000 vpm. When the paver speed was reduced to half the normal speed, hard air contents indicated that excessive vibration was beginning to occur in the localized area immediately surrounding the vibrator at a frequency of 8000 vpm. Analysis of variance testing indicated many variables and interactions to be significant at a 95% confidence level; however, the variables and interactions that were found to be significant varied from project to project. This affirms the complexity of the process for consolidating PCC.

Vibration Study for Consolidation of Portland Cement Concrete, Preprint, MLR-95-4, 1997

The Iowa Department of Transportation has discovered an increase in the occurrence of excessively vibrated portland cement concrete (PCC) pavements. The overconsolidation of PCC pavements has been observed in several projects across the state. Overconsolidation is also believed to be a factor in acceleration of premature deterioration of at least two pavement projects in Iowa. To address the problem, a research project in 1995 documented the vibratory practices of PCC slipform paving in Iowa in order to determine the effect of vibration on consolidation and air content of pavement. Paver speed, vibrator frequency, and air content relative to the location of the vibrator were studied. The study concluded that the Iowa Department of Transportation specification of 5,000 to 8,000 vibrations per minute (vpm) for slipform pavers is effective for normal paver speeds on the three projects that were examined. Excessive vibration was clearly identified on one project where a vibrator frequency of 12,000 vpm was discovered. When the paver speed was reduced to half the normal speed, hard air contents indicate that excessive vibration was beginning to occur in the localized area immediately surrounding the vibrator at a frequency of 8,000 vpm. The study also indicates that the radius of influence of the vibrators is smaller than has been claimed.

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.

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.

Ultrathin Portland Cement Concrete Overlay Extended Evaluation, Construction Report, TR-432, 2000

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, 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. The Iowa Department of Transportation (Iowa DOT) UTW project (HR-559) initiated UTW in Iowa. The project is located on Iowa Highway 21 between Iowa Highway 212 and U.S. Highway 6 in Iowa County, near Belle Plaine, Iowa. 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. This research lasted for five years, at which time it was extended an additional five years. The new phase of the project was initiated by removing cracked panels existing in the 2-inch thick PCC sections and replacing them with three inches of PCC. The project extension (TR 432) will provide an increased understanding of slab bonding conditions over a longer period, as well as knowledge regarding the behavior of the newly rehabilitated areas. In order to accomplish the goals of the project extension, Falling Weight Deflectometer (FWD) testing will continue to be conducted. Laboratory testing, field strain gage implementation, and coring will no longer be conducted. This report documents the planning and construction of the rehabilitation of HR 559 and the beginning of TR 432 during August of 1999.

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.