Transverse Cracking of Asphalt Pavements, HR-1040, Summary Report, 1982

This report summarizes the analysis of transverse cracking in asphalt pavement by a five state study team from Iowa, Kansas, Nebraska, North Dakota, and Oklahoma. The study was initiated under the sponsorship of the Federal Highway Administration and four evaluation conferences were held during the course of the study. Each state conducted a crack inventory on their asphalt pavement. An effort was made to correlate this inventory with numerous factors that were considered to be pertinent to the cracking problem. One state did indicate that there was a correlation between transverse cracking severity and the subsurface geology. The other states were unable to identify any significant factors as being the primary contributors. The analysis of the problem was divided into, (1) mix design, (2) maintenance, and (3) 3R rehabilitation. Many potential factors to be considered were identified under each of these three study divisions. There were many conclusions as to good and bad practices. One major conclusions was that a more effective crack maintenance program with early sealing was essential. Some new practices were suggested as potentially more cost effective in design, construction and maintenance. The interchange of methods and procedures by individual states yielded benefits in that other states selected practices that would be an improvement to their program.

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.

Pressure Relief and Other Joint Rehabilitation Techniques, HR-1042, 1987

A study of four major concrete pavement joint rehabilitation techniques has been conducted, including: pressure relief joints, full-depth repairs, partial-depth repairs and joint resealing. The products of this research include the following for each technique: a summary of published research, detailed documentation of the design and performance of the 36 projects, conclusions and recommendations of the state highway engineers panel, "Design and Construction Guidelines" and "Guide Specifications." The latter two products are prepared for use by state highway agencies. The results of this study are based upon a review of literature, extensive field surveys and analysis of 36 rehabilitation projects, and the experience of an expert panel of state highway engineers.

Demonstration Project 85, Video Imagery Systems for Highway Applications, HR-1047, 1990

The report describes the state of the art video equipment used and experiences gained from the 6,800 mile field test. The first objective of this project was to determine if laser disc equipment could capture and store usable roadway images while operating in a mobile environment. The second objective was to evaluate methods of using optical disc storage and retrieval features to enhance highway planning and design function. Several highway departments have attempted to use video technology to replace the traditional 16 and 35 mm film format used in photologging. These attempts have met with limited success because of the distortion caused by video technology not being capable of dealing with highway speeds. The distortion has caused many highway signs to be unreadable and, therefore, clients have labeled the technology unusable. Two methods of using optical laser disc storage and retrieval have been successfully demonstrated by Wisconsin and Connecticut Departments of Transportation. Each method provides instantaneous retrieval and linking of images with other information. However, both methods gather the images using 35 mm film techniques. The 35 mm film image is then transferred to laser disc. Eliminating the film conversion to laser disc has potential for saving $4 to $5 per logging mile. In addition to a cost savings, the image would be available immediately as opposed to delays caused by film developing and transferring to laser disc. In June and November of 1986 Iowa DOT staff and cooperating equipment suppliers demonstrated the concept of direct image capture. The results from these tests were promising and an FHWA Demonstration program established. Since 1986 technology advancements have been incorporated into the design that further improve the image quality originally demonstrated.

Review of State Comprehensive Computerized Highway Information System, HR-1053, 1987

This report presents an overview of where the computerized highway information system is now, and its status as a planning and programming tool for state highway agencies. A computerized highway information system is simply a computer linked system which can be used by many divisions of a transportation agency to obtain information to meet data reporting, analyses or other informational needs. The description of the highway information system includes: current use and status, applications, organization and system development, benefits and problems.

Design, Fabrication, and Operation of the Pavement Crack Monitor Gauge, HR-1054, 1990

A mechanical gauge was developed to monitor the movement of crack or joint openings in portland cement concrete structures, in general, and portland cement concrete pavements in particular. Designed to be inexpensive and simple to operate, this gauge is capable of recording maximum, minimum, and instantaneous crack or joint openings. Specific recommendations were made for recording minimum and maximum pavement temperature over the monitoring period. The report was written as a set of guidelines for design, fabrication, installation, and operation of the gauge as well as the temperature measuring device.

Pooled Fund Study of Premature Concrete Pavement Deterioration, HR-1063, Final Report, 1997

Recently, a number of roads have begun to exhibit the onset of deterioration at relatively early ages. Since this deterioration appears to be the result of materials issues, data concerning raw materials, design, and paving conditions have been collected and analyzed for correlation between independent variables and deterioration. This analysis shows that there is a positive and statistically significant correlation between deterioration and the following variables: alkali and sulfate content of the cementitious materials, impermeable base course, paving temperature, and the presence of fly ash. This study also concludes that there is a significant need for improvement in data collection and maintenance by many organizations responsible for the production of concrete

Deterioration of Iowa Highway Concrete Pavements: A Petrographic Study, HR-1065, 1999

Major highway concrete pavements in Iowa have exhibited premature deterioration attributed to effects of ettringite formation, alkali-silica expansive reactions, and to frost attack, or some combination of them. These pavements were constructed in the mid- 1980s as non-reinforced, dual-lane, roads ranging in thickness between 200 mm and 300 mm, with skewed joints reinforced with dowels. Deterioration was initially recognized with a darkening of joint regions, which occurred for some pavements as soon as four years after construction. Pavement condition ranges from severe damage to none, and there appeared to be no unequivocal materials or processing variables correlated with failure. Based upon visual examinations, petrographic evaluation, and application of materials models, the deterioration of concrete highway pavements in Iowa appear related to a freeze-thaw failure of the coarse aggregate and the mortar. Crack patterns sub-parallel to the concrete surface transecting the mortar fraction and the coarse aggregate are indicative of freeze-thaw damage of both the mortar and aggregate. The entrained air void system was marginal to substandard, and filling of some of the finer-sized voids by ettringite appears to have further degraded the air void system. The formation of secondary ettringite within the entrained air voids probably reflects a relatively high degree of concrete saturation causing the smaller voids to be filled with pore solution when the concrete freezes. Alkali-silica reaction (ASR) affects some quartz and shale in the fine aggregate, but is not considered to be a significant cause of the deterioration. Delayed ettringite formation was not deemed likely as no evidence of a uniform paste expansion was observed. The lack of field-observed expansion is also evidence against the ASR and DEF modes of deterioration. The utilization of fly ash does not appear to have affected the deterioration as all pavements with or without fly ash exhibiting substantial damage also exhibit significant filling of the entrained air void system, and specimens containing fly ash from sound pavements do not have significant filling. The influence of the mixture design, mixing, and placing must be evaluated with respect to development of an adequate entrained air void system, concrete homogeneity, longterm drying shrinkage, and microcracking. A high-sand mix may have contributed to the difficult mixture characteristics noted upon placement and exacerbate concrete heterogeneity problems, difficulty in developing an adequate entrained air void system, poor consolidation potential, and increased drying shrinkage and cracking. Finally, the availability of moisture must also be considered, as the secondary precipitation of ettringite in entrained air voids indicates they were at least partially filled with pore solution at times. Water availability at the base of the slabs, in joints, and cracks may have provided a means for absorbing water to a point of critical saturation.

Demonstration and Field Evaluation of Alternative Portland Cement Concrete Pavement Reinforcement Materials, HR-1069, 2003

Transverse joints are placed in portland cement concrete pavements to control the development of random cracking due to stresses induced by moisture and thermal gradients and restrained slab movement. These joints are strengthened through the use of load transfer devices, typically dowel bars, designed to transfer load across the joint from one pavement slab to the next. Epoxy coated steel bars are the materials of choice at the present time, but have experienced some difficulties with resistance to corrosion from deicing salts. The research project investigated the use of alternative materials, dowel size and spacing to determine the benefits and limitations of each material. In this project two types of fiber composite materials, stainless steel solid dowels and epoxy coated dowels were tested for five years in side by side installation in a portion of U.S. 65 near Des Moines, Iowa, between 1997 and 2002. The work was directed at analyzing the load transfer characteristics of 8-in. vs. 12-in. spacing of the dowels and the alternative dowel materials, fiber composite (1.5- and 1.88-in. diameter) and stainless steel (1.5-in. diameter), compared to typical 1.5-in. diameter epoxy-coated steel dowels placed on 12-in. spacing. Data were collected biannually within each series of joints and variables in terms of load transfer in each lane (outer wheel path), visual distress, joint openings, and faulting in each wheel path. After five years of performance the following observations were made from the data collected. Each of the dowel materials is performing equally in terms of load transfer, joint movement and faulting. Stainless steel dowels are providing load transfer performance equal to or greater than epoxy-coated steel dowels at the end of five years. Fiber reinforced polymer (FRP) dowels of the sizes and materials tested should be spaced no greater than 8 in. apart to achieve comparable performance to epoxy coated dowels. No evidence of deterioration due to road salts was identified on any of the products tested. The relatively high cost of stainless steel solid and FRP dowels was a limitation at the time of this study conclusion. Work is continuing with the subject materials in laboratory studies to determine the proper shape, spacing, chemical composition and testing specification to make the FRP and stainless (clad or solid) dowels a viable alternative joint load transfer material for long lasting portland cement concrete pavements.

Heavy Agricultural Loads on Pavements and Bridges, HR-1073, 1999

During the harvest season in Iowa, it is common to have single axle loads on secondary roads and bridges that are excessive (typical examples are grain carts) and well beyond normal load limits. Even though these excessive loads occur only during a short time of the year, they may do significant damage to pavements and bridges. In addition, the safety of some bridges may be compromised because of the excessive loads, and sometimes there may be little indication to the users that damage may be imminent. At this time there are no Iowa laws regulating axle loads allowed for agricultural equipment. This study looks at the potential problems this may cause on secondary roads and timber stringer bridges. Both highway pavement and timber bridges are evaluated in this report. A section (panel) of Iowa PCC paved county road was chosen to study the effects of heavy agricultural loads on pavements. Instrumentation was applied to the panel and a heavily loaded grain cart was rolled across. The collected data were analyzed for any indication of excessive stresses of the concrete. The second study, concerning excessive loads on timber stringer bridges, was conducted in the laboratory. Four bridge sections were constructed and tested. Two of the sections contained five stringers and two sections had three stringers. Timber for the bridges came from a dismantled bridge, and deck panels were cut from new stock. All timber was treated with creosote. A hydraulic load was applied at the deck mid-span using a foot print representing a tire from a typical grain cart. Force was applied until failure of the system resulted. The collected data were evaluated to provide indications of load distribution and for comparison with expected wheel loads for a typical heavily loaded single axle grain cart. Results of the pavement tests showed that the potential of over-stressing the pavement is a possibility. Even though most of the tension stress levels recorded were below the rupture strength of the concrete, there were a few instances where the indicated tension stress level exceeded the concrete rupture strength. Results of the bridge tests showed that when the static ultimate load capacity of the timber stringer bridge sections was reached, there was sudden loss of capacity. Prior to reaching this ultimate capacity, the load sharing between the stringers was very uniform. The failure was characterized by loss of flexural capacity of the stringers. In all tests, the ultimate test load exceeded the wheel load that would be applied by an 875 bushel single axle grain cart.

Development of In Situ Detection Methods for Materials-Related Distress (MRD) in Concrete Pavements: Phase 2, HR-1081, 2005

This project utilized information from ground penetrating radar (GPR) and visual inspection via the pavement profile scanner (PPS) in proof-of-concept trials. GPR tests were carried out on a variety of portland cement concrete pavements and laboratory concrete specimens. Results indicated that the higher frequency GPR antennas were capable of detecting subsurface distress in two of the three pavement sites investigated. However, the GPR systems failed to detect distress in one pavement site that exhibited extensive cracking. Laboratory experiments indicated that moisture conditions in the cracked pavement probably explain the failure. Accurate surveys need to account for moisture in the pavement slab. Importantly, however, once the pavement site exhibits severe surface cracking, there is little need for GPR, which is primarily used to detect distress that is not observed visually. Two visual inspections were also conducted for this study by personnel from Mandli Communications, Inc., and the Iowa Department of Transportation (DOT). The surveys were conducted using an Iowa DOT video log van that Mandli had fitted with additional equipment. The first survey was an extended demonstration of the PPS system. The second survey utilized the PPS with a downward imaging system that provided high-resolution pavement images. Experimental difficulties occurred during both studies; however, enough information was extracted to consider both surveys successful in identifying pavement surface distress. The results obtained from both GPR testing and visual inspections were helpful in identifying sites that exhibited materials-related distress, and both were considered to have passed the proof-of-concept trials. However, neither method can currently diagnose materials-related distress. Both techniques only detected the symptoms of materials-related distress; the actual diagnosis still relied on coring and subsequent petrographic examination. Both technologies are currently in rapid development, and the limitations may be overcome as the technologies advance and mature.

Construction of the Iowa Highway 60 Precast Prestressed Concrete Pavement Bridge Approach Slab Demonstration Project, HR-1085, 2007

Reconstruction of bridge approach slabs which have failed due to a loss of support from embankment fill consolidation or erosion can be particularly challenging in urban areas where lane closures must be minimized. Precast prestressed concrete pavement is a potential solution for rapid bridge approach slab reconstruction which uses prefabricated pavement panels that can be installed and opened to traffic quickly. To evaluate this solution, the Iowa Department of Transportation constructed a precast prestressed approach slab demonstration project on Highway 60 near Sheldon, Iowa in August/September 2006. Two approach slabs at either end of a new bridge were constructed using precast prestressed concrete panels. This report documents the successful development, design, and construction of the precast prestressed concrete bridge approach slabs on Highway 60. The report discusses the challenges and issues that were faced during the project and presents recommendations for future implementation of this innovative construction technique.

Evaluation of Stainless Steel Culvert Pipe in Mahaska County, Iowa, HR-2001

Corrosion of culvert pipe in Iowa in general is not a serious problem. However, it is potentially significant in some local areas. An opportunity to make a limited durability study of stainless steel pipe was presented when a local fabricating company expressed interest in a cooperative field experiment. The potential of stainless steel pipe is to reduce maintenance costs that are incurred through replacement and upkeep. A new stainless steel material, Allegheny Metal MF-1, was used in a partial fabrication demonstration and later these demonstration sections were delivered to the selected field site for placement.

Preliminary Report on the Installation of Stainless Steel Culvert Pipe in Mahaska County, Iowa, HR-2001, 1967

At the request of Mr. Arnold E. Levine, of the Levine Company, Centerville, Iowa, the Iowa State Highway Commission was asked to observe the partial fabrication of two stainless steel culvert pipes and later the Commission was asked if they would like to study their durability. These pipes were fabricated April 12, 1967 in Des Moines, Personnel of the Design and Materials Department were at the fabrication, but no Research people were present. The idea for the installation was conceived and a site selected after which the project was turned over to the Research Engineer. The stainless steel pipes presumably contained the new Allegheny Metal, MF-1, whose composition is shown in Appendix A. The primary aim of the stainless steel pipe is to reduce long term costs that are incurred through replacement and upkeep. The MF-1 has a theoretical life of infinity.

Factors Relating to Aggregate Durability in Portland Cement Concrete, HR-2022, Interim Report, 1983

Over the past several years we conducted a comprehensive study on the pore systems of limestones used as coarse aggregate in portland cement concrete (pee) and their relationship to freeze-thaw aggregate failure. A simple test called the Iowa Pore Index Test was developed and used to identify those coarse aggregates that had freeze-thaw susceptible pore systems. Basically, it identified those aggregates that could take on a considerable amount of water but only at a slow rate. The assumption was that if an aggregate would take on a considerable amount of water at a slow rate, its pore system would impede the outward movement of water through a critically saturated particle during freezing, causing particle fracture. The test was quite successful when used to identify aggregates containing susceptible pore systems if the aggregates were clean carbonates containing less than 2% or 3% insolubles. The correlation between service record, ASTM C666B and the pore index test was good, but not good enough. It became apparent over the past year that there were factors other than the pore system that could cause an aggregate to fail when used in pee. The role that silica and clay play in aggregate durability was studied.