Preventing Cracking at Diaphragm/Plate Girder Connections in Steel Bridges, HR-393, 1998

Some of the Iowa Department of Transportation (Iowa DOT) continuous, steel, welded plate girder bridges have developed web cracking in the negative moment regions at the diaphragm connection plates. The cracks are due to out-of-plane bending of the web near the top flange of the girder. The out-of-plane bending occurs in the "web-gap", which is the portion of the girder web between (1) the top of the fillet welds attaching the diaphragm connection plate to the web and (2) the fillet welds attaching the flange to the web. A literature search indicated that four retrofit techniques have been suggested by other researchers to prevent or control this type of cracking. To eliminate the problem in new bridges, AASHTO specifications require a positive attachment between the connection plate and the top (tension) flange. Applying this requirement to existing bridges is expensive and difficult. The Iowa DOT has relied primarily on the hole-drilling technique to prevent crack extension once cracking has occurred; however, the literature indicates that hole-drilling alone may not be entirely effective in preventing crack extension. The objective of this research was to investigate experimentally a method proposed by the Iowa DOT to prevent cracking at the diaphragm/plate girder connection in steel bridges with X-type or K-type diaphragms. The method consists of loosening the bolts at some connections between the diaphragm diagonals and the connection plates. The investigation included selecting and testing five bridges: three with X-type diaphragms and two with K-type diaphragms. During 1996 and 1997, these bridges were instrumented using strain gages and displacement transducers to obtain the response at various locations before and after implementing the method. Bridges were subjected to loaded test trucks traveling in different lanes with speeds varying from crawl speed to 65 mph (104 km/h) to determine the effectiveness of the proposed method. The results of the study show that the effect of out-of-plane loading was confined to widths of approximately 4 in. (100 mm) on either side of the connection plates. Further, they demonstrate that the stresses in gaps with drilled holes were higher than those in gaps without cracks, implying that the drilling hole technique is not sufficient to prevent crack extension. The behavior of the web gaps in X-type diaphragm bridges was greatly enhanced by the proposed method as the stress range and out-of-plane distortion were reduced by at least 42% at the exterior girders. For bridges with K-type diaphragms, a similar trend was obtained. However, the stress range increased in one of the web gaps after implementing the proposed method. Other design aspects (wind, stability of compression flange, and lateral distribution of loads) must be considered when deciding whether to adopt the proposed method. Considering the results of this investigation, the proposed method can be implemented for X-type diaphragm bridges. Further research is recommended for K-type diaphragm bridges.

Impact of Deck Cracking on Durability, TR-405, 2000

Concrete bridge decks subjected to corrosive environment because of the application of de-icing chemical could deteriorate at a rapid rate. In an effort to minimize corrosion of the reinforcement and the corresponding delaminations and spalls, the Iowa Department of Transportation started using epoxy-coated rebars (ECR) in the top mat of reinforcing around 1976 and in both mats 10 years later. The overall objective of this research was to determine the impact of deck cracking on durability and estimate the remaining functional service life of a bridge deck. This was accomplished by conducting a literature review, visually inspecting several bridge decks, collecting and sampling test cores from cracked and uncracked areas of bridge decks, determining the extent to which epoxy-coated rebars deteriorate at the site of cracks, and evaluating the impact of cracking on service life.

Development of In-Situ Detection Methods for Materials-Related Distress (MRD) in Concrete Pavements, July 2003

The purpose of this research was to summarize existing nondestructive test methods that have the potential to be used to detect materials-related distress (MRD) in concrete pavements. The various nondestructive test methods were then subjected to selection criteria that helped to reduce the size of the list so that specific techniques could be investigated in more detail. The main test methods that were determined to be applicable to this study included two stress-wave propagation techniques (impact-echo and spectral analysis of surface waves techniques), infrared thermography, ground penetrating radar (GPR), and visual inspection. The GPR technique was selected for a preliminary round of “proof of concept” trials. GPR surveys were carried out over a variety of portland cement concrete pavements for this study using two different systems. One of the systems was a state-of-the-art GPR system that allowed data to be collected at highway speeds. The other system was a less sophisticated system that was commercially available. Surveys conducted with both sets of equipment have produced test results capable of identifying subsurface distress in two of the three sites that exhibited internal cracking due to MRD. Both systems failed to detect distress in a single pavement that exhibited extensive cracking. Both systems correctly indicated that the control pavement exhibited negligible evidence of distress. The initial positive results presented here indicate that a more thorough study (incorporating refinements to the system, data collection, and analysis) is needed. Improvements in the results will be dependent upon defining the optimum number and arrangement of GPR antennas to detect the most common problems in Iowa pavements. In addition, refining highfrequency antenna response characteristics will be a crucial step toward providing an optimum GPR system for detecting materialsrelated distress.

Sustainable Development and Concrete Technology, May 2004

For a variety of reasons, the concrete construction industry is not sustainable. First, it consumes huge quantities of virgin materials. Second, the principal binder in concrete is portland cement, the production of which is a major contributor to greenhouse gas emissions that are implicated in global warming and climate change. Third, many concrete structures suffer from lack of durability which has an adverse effect on the resource productivity of the industry. Because the high-volume fly ash concrete system addresses all three sustainability issues, its adoption will enable the concrete construction industry to become more sustainable. In this paper, a brief review is presented of the theory and construction practice with concrete mixtures containing more than 50% fly ash by mass of the cementitious material. Mechanisms are discussed by which the incorporation of high volume of fly ash in concrete reduces the water demand, improves the workability, minimizes cracking due to thermal and drying shrinkage, and enhances durability to reinforcement corrosion, sulfate attack, and alkali-silica expansion. For countries like China and India, this technology can play an important role in meeting the huge demand for infrastructure in a sustainable manner.

Laboratory Study of Structural Behavior of Alternative Dowel Bars, April 2006

Load transfer across transverse joints has always been a factor contributing to the useful life of concrete pavements. For many years, round steel dowels have been the conventional load transfer mechanism. Many problems have been associated with the round steel dowels. The most detrimental effect of the steel dowel is corrosion. Repeated loading over time also damages joints. When a dowel is repeatedly loaded over a long period of time, the high bearing stresses found at the top and bottom edge of a bar erode the surrounding concrete. This oblonging creates multiple problems in the joint. Over the past decade, Iowa State University has performed extensive research on new dowel shapes and materials to mitigate the effects of oblonging and corrosion. This report evaluates the bearing stress performance of six different dowel bar types subjected to two different shear load laboratory test methods. The first load test is the AASHTO T253 method. The second procedure is an experimental cantilevered dowel test. The major objective was to investigate and improve the current AASHTO T253 test method for determining the modulus of dowel support, k0. The modified AASHTO test procedure was examined alongside an experimental cantilever dowel test. The modified AASHTO specimens were also subjected to a small-scale fatigue test in order to simulate long-term dowel behavior with respect to concrete joint damage. Loss on ignition tests were also performed on the GFRP dowel specimens to determine the resin content percentage. The study concluded that all of the tested dowel bar shapes and materials were adequate with respect to performance under shear loading. The modified AASHTO method yielded more desirable results than the ones obtained from the cantilever test. The investigators determined that the experimental cantilever test was not a satisfactory test method to replace or verify the AASHTO T253 method.

Retardation of Reflective Cracking using Additive 5990, February, 1987

Research was conducted in 1980 using Additive 5990 to prevent reflective cracking in asphalt cement concrete when placed over portland cement concrete. Test sections were placed with 08, 3%, 6 8 , and 9% Additive 5990 by weight of asphalt cement at mix temperatures between 375OF and 415°F with AC-5 and AC-10 grade asphalt cement. Also, sections using AC-5 and AC-10 were constructed with the normal mix temperature (not to exceed 330°F). One section was placed using AC-20 mixed at the normal mix temperature. It was concluded that the Additive 5990 did not prevent reflective cracking on this project.

Feasibility Study for Detection and Quantification of Corrosion in Bridge Barrier Rails, RB11-012, 2013

"Technical challenges exist with infrastructure that can be addressed by nondestructive evaluation (NDE) methods, such as detecting corrosion damage to reinforcing steel that anchor concrete bridge railings to bridge road decks. Moisture and chloride ions reach the anchors along the cold joint between the rails and deck, causing corrosion that weakens the anchors and ultimately the barriers. The Center for Nondestructive Evaluation at Iowa State University has experience in development of measurement techniques and new sensors using a variety of interrogating energies. This research evaluated feasibility of three technologies — x-ray radiation, ground-penetrating radar (GPR), and magnetic flux leakage (MFL) — for detection and quantification of corrosion of embedded reinforcing steel. Controlled samples containing pristine reinforcing steel with and without epoxy and reinforcing steel with 25 percent and 50 percent section reduction were embedded in concrete at 2.5 in. deep for laboratory evaluation. Two of the techniques, GPR and MFL, were used in a limited field test on the Iowa Highway 210 Bridge over Interstate 35 in Story County. The methods provide useful and complementary information. GPR provides a rapid approach to identify reinforcing steel that has anomalous responses. MFL provides similar detection responses but could be optimized to provide more quantitative correlation to actual condition. Full implementation could use either GPR or MFL methods to identify areas of concern, followed by radiography to give a visual image of the actual condition, providing the final guidance for maintenance actions." The full 103 page report and the 2 page Tech Transfer Summary are included in this link.

Investigation into Shrinkage of High-Performance Concrete Used for Iowa Bridge Decks and Overlays, TR-633, 2013

High-performance concrete (HPC) overlays have been used increasingly as an effective and economical method for bridge decks in Iowa and other states. However, due to its high cementitious material content, HPC often displays high shrinkage cracking potential. This study investigated the shrinkage behavior and cracking potential of the HPC overlay mixes commonly used in Iowa. In the study, 11 HPC overlay mixes were studied. These mixes consisted of three types of cements (Type I, I/II, and IP) and various supplementary cementitious materials (Class C fly ash, slag and metakaolin). Limestone with two different gradations was used as coarse aggregates in 10 mixes and quartzite was used in one mix. Chemical shrinkage of pastes, free drying shrinkage, autogenous shrinkage of mortar and concrete, and restrained ring shrinkage of concrete were monitored over time. Mechanical properties (such as elastic modulus and compressive and splitting tensile strength) of these concrete mixes were measured at different ages. Creep coefficients of these concrete mixes were estimated using the RILEM B3 and NCHRP Report 496 models. Cracking potential of the concrete mixes was assessed based on both ASTM C 1581 and simple stress-to-strength ratio methods. The results indicate that among the 11 mixes studied, three mixes (4, 5, and 6) cracked at the age of 15, 11, and 17 days, respectively. Autogenous shrinkage of the HPC mixes ranges from 150 to 250 microstrain and free dying shrinkage of the concrete ranges from 700 to 1,200 microstrain at 56 days. Different concrete materials (cementitious type and admixtures) and mix proportions (cementitious material content) affect concrete shrinkage in different ways. Not all mixes having a high shrinkage value cracked first. The stresses in the concrete are associated primarily with the concrete shrinkage, elastic modulus, tensile strength, and creep. However, a good relationship is found between cementitious material content and total (autogenous and free drying) shrinkage of concrete.

Cracking and Seating to Retard Reflective Cracking - Fremont County, HR-279, 1993

The concept of cracking and seating a portland cement concrete (pcc) pavement prior to laying an asphalt cement concrete (acc) surface in order to reduce reflection cracking has been around since the 1950s. With the advent of improved cracking equipment, this method gained renewed interest in the 1970s and 1980s. This project incorporated six test sections of which four were cracked and seated prior to being overlaid. Fremont County decided to utilize only a 0.9 m (3 ft) cracking pattern based on a 30 m (100 ft) trial test section. Pavement cracking appeared to be effective in reducing primarily longitudinal reflectance cracking, but only marginally successful in the reduction of transverse reflective cracking.

Reducing the Problem of Transverse Cracking, HR-232, 1985

The Iowa Department of Transportation (DOT) is continually improving the pavement management program and striving to reduce maintenance needs. Through a 1979 pavement management study, the Iowa DOT became a participant in a five state Federal Highway Administration (FHWA) study of "Transverse Cracking of Asphalt Pavements". There were numerous conclusions and recommendations but no agreement as to the major factors contributing to transverse cracking or methods of preventing or reducing the occurrence of transverse cracking. The project did focus attention on the problem and generated ideas for research. This project is one of two state funded research projects that were a direct result of the FHWA project. Iowa DOT personnel had been monitoring temperature susceptibility of asphalt cements by the Norman McLeod Modified Penetration Index. Even though there are many variables from one asphalt mix to another, the trend seemed to indicate that the frequency of transverse cracking was highly dependent on the temperature susceptibility. Research project HR-217 "Reducing the Adverse Effects of Transverse Cracking" was initiated to verify the concept. A final report has been published after a four-year evaluation. The crack frequency with the high temperature susceptible asphalt cement was substantially greater than for the low temperature susceptible asphalt cement. An increased asphalt cement content in the asphalt treated base also reduced the crack frequency. This research on prevention of transverse cracking with fabric supports the following conclusions: 1. Engineering fabric does not prevent transverse cracking of asphalt cement concrete. 2. Engineering fabric may retard the occurrence of transverse cracking. 3. Engineering fabric does not contribute significantly to the structural capability of an asphalt concrete pavement.

High Range Water Reducer in Portland Cement Concrete Made with D-Cracking Susceptible Coarse Aggregate, HR-1021, 1980

The objective of this research was to determine of the use of High Range Water Reducers (HRWR) (resulting in a lower water content ratio) with a D-cracking susceptible crushed limestone coarse aggregate would yield significant improvement in the durability.

Reducing the Adverse Effects of Transverse Cracking, HR-217, 1984

This research was initiated to identify methods of reducing the occurrence of transverse cracking. Eight (four repetitive) research sections were established to study three variations in the asphalt concrete pavement. The first variation was the comparison of low- and high-temperature-susceptible asphalt cement (AC) from two different sources. The second variable was to saw and seal transverse joints at spacings varying from 40 to 100 ft. The third variable was to increase the AC content in the asphalt treated base by 1 percent. The research sections were constructed with relatively few problems. Crack and joint surveys have been conducted on all research sections at intervals of less than 1 year since construction. No cracking was identified after the first winter season. The sawed joints also remained sealed through the first winter. At an age of approximately 1 1/2 years there was substantial cracking of the high-temperature-susceptible AC sections and substantial failure of the sealant material in the sawed joints. After almost 4 years, the asphalt pavement constructed with the high-temperature-susceptible AC produced a crack interval of 35 ft, the low-temperature-susceptible AC yielded an interval of 170 ft, and the low-temperature-susceptible AC with an increased AC content yielded an interval of 528 ft. The Pen-Vis number is an effective measure of temperature susceptibility of asphalt cements. The frequency of transverse cracking is affected by the temperature susceptibility of the AC. An increased AC content also reduces the frequency of transverse cracking.

Fatigue and Residual Stress Investigation of Composite Prestressed Steel Beams, HR-74, 1963

Two composite, prestressed, steel beams, fabricated by slightly different methods, were fatigue tested to destruction. Stresses and deflections were measured at regular intervals, and the behavior of each beam as failure progressed was recorded. Residual stresses were then evaluated by testing segments of each beam. An attempt was made to assess the effects of the residual stresses on fatigue strength.

Glasgrid Fabric to Control Reflective Cracking, HR-535, 1990

The major problem with durability of asphalt cement concrete (ACC) overlays to rehabilitate jointed portland cement concrete (PCC) pavement comes from reflective cracking. The objective of this research was to evaluate the effectiveness of Glasgrid in regard to preventing reflection cracking. Glasgrid is a glass fiber mesh with 1/2 inch by 1 inch openings (Figure 1). Each strand is composed of many small glass fibers. After the grid is formed, it is coated with a polymer modified asphalt cement. In 1986, four experimental Glasgrid test sections were incorporated into Polk County project IR-35-2(191)67--12-77 on Interstate 35 from IA 5 to the west 1-80 interchange on the west edge of Des Moines, Single and double layers of Glasgrid were placed over transverse cracks and joints of the existing PCC pavement. The Glasgrid was placed on the PCC pavement for one section and between lifts of the ACC resurfacing on the other three sections. The four Glasgrid sections were compared to two sections without Glasgrid for four years. The sections were reviewed annually to determine how many cracks or joints had reflected through the resurfacing. Glasgrid placed on the PCC pavement was more effective at preventing reflection cracking than Glasgrid between lifts of AC resurfacing. In general, Glasgrid yielded a small reduction or retardation in the amount of reflection cracking, but not sufficient to justify additional expense for the use of Glasgrid.

Deicing Salt Corrosion with and without Inhibitors, MLR-87-8, 1989

Chloride ion penetration through concrete to reinforcing steel is causing the premature deterioration of numerous bridge decks in Iowa. The purpose of the research reported in this paper was to determine whether any of several additives or alternative deicing chemicals could inhibit corrosion of reinforcing steel. The deicers tested were calcium magnesium acetate (CMA), CMA plus NaCl (NaCl: sodium chloride), Quicksalt plus PCI, and CG-90, a polyphosphate solution being developed by Cargill. Two tests were established. First, steel coupons were placed in a 15% solution of a deicer and distilled water to determine which alternative deicer would cause the least amount of corrosion in solution. The coupons were weighed periodically to determine each coupon's weight loss from corrosion. The second test involved ponding a 15% solution of each material on reinforced concrete blocks. Weekly copper-copper sulfate electrical half-cell (CSE) potential readings were taken on each block to determine whether corrosive activity was occurring at the steel surface. When the ponding research was concluded, concrete samples were taken from one of the three blocks ponded with each deicer. The samples were used to determine the chloride ion content at the level of the steel. Results show that all the deicers were less corrosive than NaCl. Only pure CMA, however, significantly inhibited the corrosion of steel embedded in concrete.