Performance Evaluation Of Iowa Bridge Decks Constructed With Epoxy-Coated Reinforcing Bars, RB06-011, 2011

Epoxy coatings have been used on the embedded reinforcing bars of bridge decks since the mid-1970s to mitigate deterioration caused by chloride-induced corrosion. The use of chloride-based deicers became common in the early 1960s and caused corrosion of conventional uncoated bars in bridge decks within 5 to 10 years of commencement of deicer applications. In response to this rapid deterioration, the National Bureau of Standards researched coatings to protect the reinforcement (National Bureau of Standards, 1975), resulting in the development of epoxy-coated reinforcing bars, which were used in bridge decks beginning in 1973. While corrosion-related deterioration has been prevalent on bridge decks with uncoated reinforcing bars in northern climates where the use of deicing salts is common, bridge decks constructed after 1973 with epoxy-coated reinforcing have shown good corrosion resistance with only limited exceptions. On the whole, previous laboratory and field studies regarding the performance of epoxy-coated reinforcing bars are very promising; however, some laboratory and field studies have yielded differing results. In recent years, maintenance personnel for the Iowa Department of Transportation (Iowa DOT) have reportedly performed patch repairs to some bridge decks reinforced with epoxy-coated bars. At one such bridge, the southbound US 65 bridge (Bridge No. 7788.5L065) over the Union Pacific Railroad near Bondurant in Polk County, Iowa, deck repairs were performed by Iowa DOT maintenance personnel in the Spring of 2010, based on our communications regarding this topic with Mr. Gordon Port of the Iowa DOT. These repairs were observed by engineers from the Iowa DOT Office of Bridges and Structures, who reported that significant corrosion was found at a number of epoxy-coated reinforcing bars uncovered during this patch work. These repairs were reportedly performed at spalls and delaminated areas corresponding to cracks over transverse reinforcing bars, and involved careful removal of the concrete from over the bars. Figures 1 through 4 contain photographs provided by Iowa DOT personnel showing the removal process (Figure 1), the conditions encountered (Figures 2 and 3), and close-up views of the corroded reinforcing (Figure 4). As a result of these observations, the Iowa Department of Transportation has requested this study to gain further understanding of the long-term performance of bridge decks reinforced with epoxy-coated bars. The two main objectives of this study are to determine the long-term effectiveness of the epoxy coatings and to determine the potential causes for the deterioration at locations where corrosion has occurred. Wiss, Janney, Elstner Associates, Inc. (WJE) and the Iowa DOT identified eight different bridge decks across Iowa for this study that were constructed using epoxy-coated reinforcing bars. A field investigation consisting of visual inspections, a delamination survey, a concrete cover survey, electrical testing for susceptibility to corrosion, and concrete sampling was conducted within a survey area deemed to be representative of the condition of each bridge deck. Laboratory testing, including chloride ion content testing, characterization of the extracted bars, petrographic examination of the concrete, and carbonation testing, was conducted on the core samples taken from each bridge deck.

Production of Asphalt Rubber Concrete by the Dry Process, HR-1062, 1994

Disposal of used tires has been a problem throughout the United States. The 1991 Intermodal Surface Transportation Efficiency Act (ISTEA) requires the use of recycled rubber in asphalt concrete starting in FY94. A moratorium has delayed this requirement until FY95. The Iowa DOT has researched six projects using crumb rubber modifier in asphalt concrete using the wet process. This process involves using a blender-reactor to blend the asphalt cement and crumb rubber. Using the wet process the asphalt cement has to reach a hotter temperature, than is normally required, for reaction to occur. The wet process is also much more expensive than conventional asphalt. This research deals with using a dry process to incorporate crumb rubber into the asphalt concrete mix. The project was constructed by Western Engineering of Harlan, Iowa, on IA 37 between Earling, Iowa and US 59. It was completed in September 1993. Western Engineering used a double drum mixer to produce the crumb rubber modified asphalt concrete by the dry process. The production and construction went well with minor difficulty and the dry process is a less expensive procedure for producing crumb rubber modified asphalt concrete.

1022-013 Dry Run Creek Watershed Final Report

The Dry Run Creek Watershed received a biological impairment in 2002 after sampling conducted by the Department of Natural Resources revealed a lack in the diversity and abundance of aquatic life along a 2.8 mile reach of stream along the Southwest Branch. Among the primary stressors identified were hydrologic change, increased stormsewer inputs, lack of available habitat, and sedimentation. Goals put forth by the Watershed Management Plan and the preliminary Total Maximum Daily Load (TMDL) study center around the reduction in storm sewer inputs. The goal set forth by the TMDL is the reduction of connected impervious surface (CIS) to 10% in each of the creek’s subwatersheds as a surrogate for other stressors. Grant funding is being sought for the construction of two bioretention cells and a green roof to treat the first flush of runoff from a new 400 unit student housing structure and connected parking surfaces totaling 5.16 acres. In addition, a monitoring program will continue to be coordinated through a partnership with the Department of Natural Resources IOWATER program and locally led volunteer efforts which will allow us to track the progress of the watershed. Funding for administration, outreach, and assessment will be provided through existing 319 grants. Implementation of these practices will occur in phases over the course of a two year period.

07033-013 Dry Run Creek Sub-watershed Final Report

This watershed project will provide technical and financial assistance to improve surface and groundwater quality. This will be accomplished by installing an alternative tile outlet for 3 agricultural drainage wells (ADWs) and providing incentives to implement nutrient and pest management.

05046-017 Dry Run Creek Watershed Final Report

Dry Run Creek Watershed was designated an impaired waterbody by DNR in 2002, following an assessment of the biota in the stream by DNR Biologist, Tom Wilton. Subsequent studies by IOWATER Snapshot effort in 2003, found e-coli bacteria concentrations and high nitrate readings in excess of the State of Iowa limits for recreational streams. The Dry Run Creek Watershed Improvement Project is comprised of five major components. Three components will feature demonstrations of structural best management practices (BMPs) to protect water quality in Dry Run Creek. The fourth is an educational workshop to "kick-off" the initiative and background the stakeholders of the watershed in new stormwater management strategies for water quality protection. The fifth is a monitoring program that will provide data on the effectiveness of the practices to be demonstrated. Measurable outcomes from these projects include monitoring to document the effectiveness of infiltration­ based BMPs to reduce pollutant loading in urban stormwater runoff and reducing the volume of stormwater discharged directly into Dry Run Creek via storm sewer flows. Understanding of and social acceptance of new stormwater strategies and practices will also be monitored by surveys of watershed stakeholders and compared to findings of a survey done before the start of the project.