Iowa Power Fund Board Project Report Update, July 29, 2009

Amana Farms is using an anaerobic digestion, which is a two-stage digester that converts manure and other organic wastes into three valuable by-products: 1) Biogas – to fuel an engine/generator set to create electricity; 2) Biosolids - used as a livestock bedding material or as a soil amendment; 3) Liquid stream - will be applied as a low-odor fertilizer to growing crops. (see Business Plan appendix H) The methane biogas will be collected from the two stages of the anaerobic digestion vessel and used for fuel in the combined heat and power engine/generator sets. The engine/generator sets are natural gasfueled reciprocating engines modified to burn biogas. The electricity produced by the engine/generator sets will be used to offset on-farm power consumption and the excess power will be sold directly to Amana Society Service Company as a source of green power. The waste heat, in the form of hot water, will be collected from both the engine jacket liquid cooling system and from the engine exhaust (air) system. Approximately 30 to 60% of this waste heat will be used to heat the digester. The remaining waste heat will be used to heat other farm buildings and may provide heat for future use for drying corn or biosolids. The digester effluent will be pumped from the effluent pit at the end of the anaerobic digestion vessel to a manure solids separator. The mechanical manure separator will separate the effluent digested waste stream into solid and liquid fractions. The solids will be dewatered to approximately a 35% solid material. Some of the separated solids will be used by the farm for a livestock bedding replacement. The remaining separated solids may be sold to other farms for livestock bedding purposes or sold to after-markets, such as nurseries and composters for soil amendment material. The liquid from the manure separator, now with the majority of the large solids removed, will be pumped into the farm’s storage lagoon. A significant advantage of the effluent from the anaerobic digestion treatment process is that the viscosity of the effluent is such that the liquid effluent can now be pumped through an irrigation nozzle for field spreading.

Rubber Buffings for Bridge Approach Expansion Joints, MLR-01-01, 2001

Many of the bridges in the state of Iowa have type ‘CF’, ‘EE’, or ‘EF’ expansion joints installed in the bridge approach slabs. These joints, which are typically 4” wide, are currently filled with a foam expansion joint material that is covered with a sealant. Over time the sealant begins to pull off of the walls of the joint and it ultimately fails. The joint, which is now exposed to the weather, is then filled with water and solids. The foam joint material, which is lighter than water, floats out of the joint onto the highway. This foam resembles a large 4” X 6” plank and poses a threat to motorists. A possible solution to this problem would be to replace the foam material with rubber buffings. Rubber buffings are a by-product of the tire retread industry.

Polymer Additive Ductilad D1002 in a Bituminous Seal Coat, HR-2035, 1994

Seal coat and chip seal treatments are commonly used as an economical treatment to provide a new surface to an old asphalt roadway. To be successful, the aggregate or chips must be held in place on the roadway by the asphalt binder over a long period of time. It is common, over time, that the binder becomes aged and brittle and loses its ability to be flexible and hold the aggregate in place. Modifiers have been introduced to extend the life and adhesion characteristics of asphaltic binders.

Wind Loads on Dynamic Message Cabinets and Behavior of Supporting Trusses, TR-612, 2013

Large Dynamic Message Signs (DMSs) have been increasingly used on freeways, expressways and major arterials to better manage the traffic flow by providing accurate and timely information to drivers. Overhead truss structures are typically employed to support those DMSs allowing them to provide wider display to more lanes. In recent years, there is increasing evidence that the truss structures supporting these large and heavy signs are subjected to much more complex loadings than are typically accounted for in the codified design procedures. Consequently, some of these structures have required frequent inspections, retrofitting, and even premature replacement. Two manufacturing processes are primarily utilized on truss structures - welding and bolting. Recently, cracks at welding toes were reported for the structures employed in some states. Extremely large loads (e.g., due to high winds) could cause brittle fractures, and cyclic vibration (e.g., due to diurnal variation in temperature or due to oscillations in the wind force induced by vortex shedding behind the DMS) may lead to fatigue damage, as these are two major failures for the metallic material. Wind and strain resulting from temperature changes are the main loads that affect the structures during their lifetime. The American Association of State Highway and Transportation Officials (AASHTO) Specification defines the limit loads in dead load, wind load, ice load, and fatigue design for natural wind gust and truck-induced gust. The objectives of this study are to investigate wind and thermal effects in the bridge type overhead DMS truss structures and improve the current design specifications (e.g., for thermal design). In order to accomplish the objective, it is necessary to study structural behavior and detailed strain-stress of the truss structures caused by wind load on the DMS cabinet and thermal load on the truss supporting the DMS cabinet. The study is divided into two parts. The Computational Fluid Dynamics (CFD) component and part of the structural analysis component of the study were conducted at the University of Iowa while the field study and related structural analysis computations were conducted at the Iowa State University. The CFD simulations were used to determine the air-induced forces (wind loads) on the DMS cabinets and the finite element analysis was used to determine the response of the supporting trusses to these pressure forces. The field observation portion consisted of short-term monitoring of several DMS Cabinet/Trusses and long-term monitoring of one DMS Cabinet/Truss. The short-term monitoring was a single (or two) day event in which several message sign panel/trusses were tested. The long-term monitoring field study extended over several months. Analysis of the data focused on trying to identify important behaviors under both ambient and truck induced winds and the effect of daily temperature changes. Results of the CFD investigation, field experiments and structural analysis of the wind induced forces on the DMS cabinets and their effect on the supporting trusses showed that the passage of trucks cannot be responsible for the problems observed to develop at trusses supporting DMS cabinets. Rather the data pointed toward the important effect of the thermal load induced by cyclic (diurnal) variations of the temperature. Thermal influence is not discussed in the specification, either in limit load or fatigue design. Although the frequency of the thermal load is low, results showed that when temperature range is large the restress range would be significant to the structure, especially near welding areas where stress concentrations may occur. Moreover stress amplitude and range are the primary parameters for brittle fracture and fatigue life estimation. Long-term field monitoring of one of the overhead truss structures in Iowa was used as the research baseline to estimate the effects of diurnal temperature changes to fatigue damage. The evaluation of the collected data is an important approach for understanding the structural behavior and for the advancement of future code provisions. Finite element modeling was developed to estimate the strain and stress magnitudes, which were compared with the field monitoring data. Fatigue life of the truss structures was also estimated based on AASHTO specifications and the numerical modeling. The main conclusion of the study is that thermal induced fatigue damage of the truss structures supporting DMS cabinets is likely a significant contributing cause for the cracks observed to develop at such structures. Other probable causes for fatigue damage not investigated in this study are the cyclic oscillations of the total wind load associated with the vortex shedding behind the DMS cabinet at high wind conditions and fabrication tolerances and induced stresses due to fitting of tube to tube connections.

1009-004 Lost Island Lake Watershed Final Report

The Lost Island Lake watershed is located in the prairie pothole region, a region dotted with glacial wetlands and shallow lakes. At 1,180 acres, Lost Island Lake is the state's fifth largest natural lake and its watershed is comprised of nearly 1,000 acres of wetland habitat, including Iowa 's largest natural wetland – Barringer Slough. Unfortunately, Lost Island and its associated wetlands are not functioning to their fullest ecological and water quality potential. In 2002 and 2004, Lost Island Lake was categorized as '·impaired'" on Iowa's Impaired Waters List. Frequent algal blooms and suspended solids drastically increase turbidity levels resulting in its impairment. To investigate these concerns, a two-year study and resulting Water Quality Improvement Plan were completed. The water quality study identified an overabundance of non-native common carp (Cyprinus carpio) in the lake and its surrounding wetlands as a primary cause of impairment. The goal of the Lost Island Lake Watershed Enhancement Project is to restore ecological health to Lost Island Lake and its intricate watershed resulting in improved water quality and a diverse native plant and wildlife community. The purpose of this grant is to obtain funding for the construction of two combination fish barriers and water control structures placed at key locations in the watershed within the Blue Wing Marsh complex. Construction of the fish barriers and water control structures would aid restoration efforts by preventing spawning common carp from entering wetlands in the watershed and establishing the ability to manage water levels in large wetland areas. Water level management is crucial in wetland health and exotic fish control. These two structures are part of a larger construction project that involves a total of four combination fish barriers and water control structures and one additional fish barrier. The entire Lost Island Lake Watershed Enhancement Project is a multi-year project, but the construction phase for the fish barriers and water control structures will be completed before December 31, 2011.

06004-003 Big Sioux River Watershed Final Report

Controlling and managing manure-contaminated runoff is a responsibility of every livestock producer. The minimum requirement of all confined feeding operations in Iowa, regardless of size, is to settle solids. Two separate watershed assessments conducted in 2003-2004 by the Lyon SWCD of 141 feedlot sites indicated only 29% have solid settling basins in place. Regulating agencies generally recommend a holding pond followed by irrigation land application which require large capital investments, specialized machinery and additional management skill sets. Producers are looking for more cost-effective alternatives for controlling feedlot runoff and regulating agencies need to know these alternatives will protect the environment.

Bituminous Mixes Prepared with Foamed Asphalt, Iowa Highway Research Board Bulletin No. 18, 1960

A contract for Project HR-20 "Treating Loess, Fine Sands and Soft Limestones with Liquid Binders" of the Iowa Highway Research Board was awarded in December, 1951, to the Iowa Engineering Experiment Station of Iowa State University as its Project 295-S. By 1954 the studies of the fine materials and asphalts had progressed quite well, and a method of treating the fine materials, called the atomization process, had been applied. A study was begun in 1954 to see if some of the problems of the atomization process could be solved with the use of foamed asphalt. Foamed asphalt has several advantages. The foaming of asphalt increases its volume, reduces its viscosity, and alters its surface tension so that it will adhere tenaciously to solids. Foamed asphalt displaces moisture from the surface of a solid and coats it with a thin film. Foamed asphalt can permeate deeply into damp soils. In the past these unusual characteristics were considered nuisances to be avoided if possible.