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.

Core Analysis of Portland Cement Concrete Slip Formed Barriers, January 2000

Premature deterioration of slip formed portland cement concrete (PCC) barriers is an ongoing problem in the Iowa Primary and Interstate highway system. The requirement to have a concrete mix which can be sufficiently pliable to be readily molded into the barrier shape and yet be sufficiently stiff to maintain a true shape and height immediately after molding is difficult to meet. A concrete mix which is stiff enough to maintain its shape immediately after molding is usually difficult to work with. It often contains open or hidden tears and large voids. One way to minimize the molding resistance is by additional vibration. If intensive vibration is applied, the entrapped air voids and tears in the concrete can usually be eliminated, however, in that process, the essential entrained air content can also be lost. In the evaluation of slip formed PCC barriers, it is common to find large voids, tears and a low entrained air content, all contributing to premature deterioration. A study was initiated to evaluate core samples taken from good and from bad appearing areas of various median barriers. Evaluations were done covering visual appearance, construction information, air content and chloride content.

On The Spot Damage Detection Methodology for Highway Bridges, July 2010

Vibration-based damage identification (VBDI) techniques have been developed in part to address the problems associated with an aging civil infrastructure. To assess the potential of VBDI as it applies to highway bridges in Iowa, three applications of VBDI techniques were considered in this study: numerical simulation, laboratory structures, and field structures. VBDI techniques were found to be highly capable of locating and quantifying damage in numerical simulations. These same techniques were found to be accurate in locating various types of damage in a laboratory setting with actual structures. Although there is the potential for these techniques to quantify damage in a laboratory setting, the ability of the methods to quantify low-level damage in the laboratory is not robust. When applying these techniques to an actual bridge, it was found that some traditional applications of VBDI methods are capable of describing the global behavior of the structure but are most likely not suited for the identification of typical damage scenarios found in civil infrastructure. Measurement noise, boundary conditions, complications due to substructures and multiple material types, and transducer sensitivity make it very difficult for present VBDI techniques to identify, much less quantify, highly localized damage (such as small cracks and minor changes in thickness). However, while investigating VBDI techniques in the field, it was found that if the frequency-domain response of the structure can be generated from operating traffic load, the structural response can be animated and used to develop a holistic view of the bridge’s response to various automobile loadings. By animating the response of a field bridge, concrete cracking (in the abutment and deck) was correlated with structural motion and problem frequencies (i.e., those that cause significant torsion or tension-compression at beam ends) were identified. Furthermore, a frequency-domain study of operational traffic was used to identify both common and extreme frequencies for a given structure and loading. Common traffic frequencies can be compared to problem frequencies so that cost-effective, preventative solutions (either structural or usage-based) can be developed for a wide range of IDOT bridges. Further work should (1) perfect the process of collecting high-quality operational frequency response data; (2) expand and simplify the process of correlating frequency response animations with damage; and (3) develop efficient, economical, preemptive solutions to common damage types.

Evaluation of the RapidAir 457 Air Void Analyzer, March 2012

An adequate air void system is imperative to produce concrete with freeze-thaw durability in a wet freeze environment such as found in Iowa. Specifications rely on a percentage of air obtained in the plastic state by the pressure meter. Actual, in place air contents, of some concrete pavements in Iowa, have been found with reduced air content due to a number of factors such as excessive vibration and inadequate mixing. Determining hardened air void parameters is a time consuming process involving potential for human error. The RapidAir 457 air void analyzer is an automated device used to determine hardened air void parameters. The device is used in Europe and has been shown to quickly produce accurate and repeatable hardened air results. This research investigates how well the RapidAir 457 results correlate to plastic air content and the image analysis air technique. The repeatability and operator variation were also investigated, as well as, the impact of aggregate porosity and selection of threshold value on hardened air results.

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.

Integration of Bridge Damage Detection Concepts and Components (3 volumes), TR-636, 2013

This work is divided into three volumes: Volume I: Strain-Based Damage Detection; Volume II: Acceleration-Based Damage Detection; Volume III: Wireless Bridge Monitoring Hardware. Volume I: In this work, a previously-developed structural health monitoring (SHM) system was advanced toward a ready-for-implementation system. Improvements were made with respect to automated data reduction/analysis, data acquisition hardware, sensor types, and communication network architecture. The statistical damage-detection tool, control-chart-based damage-detection methodologies, were further investigated and advanced. For the validation of the damage-detection approaches, strain data were obtained from a sacrificial specimen attached to the previously-utilized US 30 Bridge over the South Skunk River (in Ames, Iowa), which had simulated damage,. To provide for an enhanced ability to detect changes in the behavior of the structural system, various control chart rules were evaluated. False indications and true indications were studied to compare the damage detection ability in regard to each methodology and each control chart rule. An autonomous software program called Bridge Engineering Center Assessment Software (BECAS) was developed to control all aspects of the damage detection processes. BECAS requires no user intervention after initial configuration and training. Volume II: In this work, a previously developed structural health monitoring (SHM) system was advanced toward a ready-for-implementation system. Improvements were made with respect to automated data reduction/analysis, data acquisition hardware, sensor types, and communication network architecture. The objective of this part of the project was to validate/integrate a vibration-based damage-detection algorithm with the strain-based methodology formulated by the Iowa State University Bridge Engineering Center. This report volume (Volume II) presents the use of vibration-based damage-detection approaches as local methods to quantify damage at critical areas in structures. Acceleration data were collected and analyzed to evaluate the relationships between sensors and with changes in environmental conditions. A sacrificial specimen was investigated to verify the damage-detection capabilities and this volume presents a transmissibility concept and damage-detection algorithm that show potential to sense local changes in the dynamic stiffness between points across a joint of a real structure. The validation and integration of the vibration-based and strain-based damage-detection methodologies will add significant value to Iowa’s current and future bridge maintenance, planning, and management Volume III: In this work, a previously developed structural health monitoring (SHM) system was advanced toward a ready-for-implementation system. Improvements were made with respect to automated data reduction/analysis, data acquisition hardware, sensor types, and communication network architecture. This report volume (Volume III) summarizes the energy harvesting techniques and prototype development for a bridge monitoring system that uses wireless sensors. The wireless sensor nodes are used to collect strain measurements at critical locations on a bridge. The bridge monitoring hardware system consists of a base station and multiple self-powered wireless sensor nodes. The base station is responsible for the synchronization of data sampling on all nodes and data aggregation. Each wireless sensor node include a sensing element, a processing and wireless communication module, and an energy harvesting module. The hardware prototype for a wireless bridge monitoring system was developed and tested on the US 30 Bridge over the South Skunk River in Ames, Iowa. The functions and performance of the developed system, including strain data, energy harvesting capacity, and wireless transmission quality, were studied and are covered in this volume.

Field Measurements of Ice Scraping Loads on Front Mounted Plow Blades, HR-374, 1997

Removal of ice from roads is of the more challenging task in winter highway maintenance. The best mechanical method is to use a truck with underbody plow blade, but such equipment is not available to all agencies charged with winter maintenance operations. While counties and cities often use motor graders to scrape ice, it would be of great benefit if front mounted plows could be used effectively for ice removal. To reveal and understand the factors that influence the performance of these plows, measurement of the forces experienced by the plow blades during ice scraping is desirable. This study explores the possibility of using accelerometers to determine the forces on a front-mounted plow when scraping ice. The plow was modeled by using a dynamic approach. The forces on the plow were to be determined by the measurement of the accelerations of the plow. Field tests were conducted using an "as is" front-mounted plow instrumented with accelerometers. The results of the field tests indicate that in terms of ice removal, the front-mounted plow is not favorable equipment. The major problem in this study is that the front mounted plow was not able to cut ice, and therefore experienced no significant scraping forces. However, the use of accelerometers seems to be promising for analyzing the vibration problems of the front-mounted plow.

On the spot damage detection methodology for highway bridges (tech transfer summary)

The objective of this work was to develop a low-cost portable damage detection tool to assess and predict damage areas in highway bridges. The proposed tool was based on standard vibration-based damage identification (VBDI) techniques but was extended to a new approach based on operational traffic load. The methodology was tested using numerical simulations, laboratory experiments, and field testing.

Vibratory Effects in Reinforced Portland Cement Concrete Pavement, MLR-97-2, 1997

A double mat of reinforcement steel consisting of No. 5 bars was placed in the longitudinal and transverse directions in a 26' wide, 10" thick pavement. The bars were placed on 12" centers with 2" of cover from the top and bottom surfaces. The special reinforcement is to provide additional strength in the pavement over an area of old coal mine tunnels. Auxiliary and standard paver vibrators were used to consolidate the concrete. There was concern that over-vibration could be occurring in some areas and also that a lack of consolidation may be occurring under the steel bars in some areas. A core evaluation study of the pavement was developed. The results showed that the consolidation and the air contents were satisfactory. Additional paving with reinforcement in the same area should use the same or similar method and amount of vibration as was used in the area evaluated in this study.

Iowa Development of Rubblized Concrete Pavement Base - Mills County, HR-315, 1995

Iowa counties have tried to rehabilitate deteriorating portland cement concrete (PCC) pavements with standard overlays, placement of engineering fabric, rock, open graded bituminous mixes and cracking and seating. While these methods prolong the life of the road, the cracks in the old pavement have eventually reflected to the surface. One possible alternative for rehabilitating severely deteriorated roads and preventing reflective cracking is the rubblization process. The objective of this research project was to rehabilitate and evaluate a severely deteriorated PCC roadway using a rubblization process. A 3.0 km (1.9 mi) section of L63 in Mills County was selected for this research. The road was divided into 16 sections. A resonate frequency vibration pavement breaker was used to rubblize the existing pavement. The variables of rubblization, drainage, and ACC overlay depths of 75 mm (3 in.), 100 mm (4 in.), and 125 mm (5 in.) were evaluated. The research on rubblized concrete pavement bases support the following conclusions: (1) The rubblization process prevents reflective cracking; (2) Edge drains improved the structural rating of the rubblized roadway; (3) An ACC overlay of 125 mm (5 in.) on a rubblized base provided an excellent roadway regardless of soil and drainage conditions; (4) An ACC overlay of 75 mm (3 in.) on a rubblized base can provide a good roadway if the soil structure below the rubblized base is stable and well drained; and (5) The Road Rater structural ratings of the rubblized test sections for this project are comparable to the nonrubblized test sections.

Field Evaluation of Quality Management Concrete, MLR-97-3, 1998

Quality management concrete allows the contractor to develop the mix design for the portland cement concrete. This research was initiated to gain knowledge about contractor mix designs. An experiment was done to determine the variation in cylinders, beams, and cores that could be used to test the strength of the contractor's mix. In addition, the contractor's cylinder strengths and gradations were analyzed for statistical stability and process capability. This research supports the following conclusions: (1) The mold type used to cast the concrete cylinders had an effect on the compressive strength of the concrete. The 4.5-in. by 9-in. (11.43-cm by 22.86-cm) cylinders had lower strength at a 95% confidence interval than the 4-in. by 8-in. (10.16-cm by 20.32-cm) and 6-in. by 12-in. (15.24-cm by 30.48-cm) cylinders. (2) The low vibration consolidation effort had the lowest strength of the three consolidation efforts. In particular, an interaction occurred between the low vibration effort and the 4.5-in. by 9-in. (11.43-cm by 22.86-cm) mold. This interaction produced very low compressive strengths when compared with the other consolidation efforts. (3) A correlation of 0.64 R-squared was found between the 28 day cylinder and 28 day compressive strengths. (4) The compressive strength results of the process control testing were not in statistical control. The aggregate gradations were mostly in statistical control. The gradation process was capable of meeting specification requirements. However, many of the sieves were off target. (5) The fineness modulus of the aggregate gradations did not correlate well with the strength of the concrete. However, this is not surprising considering that the gradation tests and the strength tests did not represent the same material. In addition, the concrete still has many other variables that will affect its strength that were not controlled.

Evaluation of Deterioration on US 20 in Webster County, MLR-91-1, 1991

Ten miles of U.S. Highway 20 in Webster County began to show deterioration in 1990. Any deterioration was unexpected, since the road was just constructed in 1986 and 1987. The deterioration looked much like the staining and cracking of D-cracking. Cracking was found on 391 joints throughout the 10 mile four lane divided highway. Evaluation of cores from the project reveal low air contents at those locations where cracking is occurring. The cause of the low air contents can only be speculated on. A possible cause may be the vibration from the paver coupled with the additional vibration at the joints. Other projects constructed in 1986 and 1987 with the same equipment show no signs of distress.

Construction of a Bridge Floor Using High Range Water Reducer, Construction Report, HR-192, 1978

The use of a high range water reducer in bridge floors was initiated by an Iowa Highway Research Board project (HR-192) in 1977 for two basic reasons. One was to determine the feasibility of using a high range water reducer (HRWR) in bridge floor concrete using conventional concrete proportioning, transporting and finishing equipment. The second was to determine the performance and protective qualities against chloride intrusion of a dense concrete bridge floor by de-icing agents used on Iowa's highways during winter months. This project was basically intended to overcome some problems that developed in the original research project. The problems alluded to are the time limits from batching to finishing; use of a different type of finishing machine; need for supplemental vibration on the surface of the concrete during the screeding operation and difficulty of texturing. The use of a double oscillating screed finishing machine worked well and supplemental vibration on one of the screeds was not needed. The limit of 45 minutes from batching the concrete to placement on the deck was verified. This is a maximum when the HRWR is introduced at the batch plant. The problem of texturing was not solved completely but is similar to our problems on the dense "Iowa System" overlay used on bridge deck repair projects. This project reinforced some earlier doubts about using truck transit mixers for mixing and transporting concrete containing HRWR when introduced at the batch plant.

Treating Iowa's Marginal Aggregates and Soils by Foamix Process, HR-212, 1980

Quality granular materials suitable for building all-weather roads are not uniformly distributed throughout the state of Iowa. For this reason the Iowa Highway Research Board has sponsored a number of research programs for the purpose of developing new and effective methods for making use of whatever materials are locally available. This need is ever more pressing today due to the decreasing availability of road funds and quality materials, and the increasing costs of energy and all types of binder materials. In the 1950s, Professor L. H. Csanyi of Iowa State University had demonstrated both in the laboratory and in the field, in Iowa and in a number of foreign countries, the effectiveness of preparing low cost mixes by stabilizing ungraded local aggregates such as gravel, sand and loess with asphalt cements using the foamed asphalt process. In this process controlled foam was produced by introducing saturated steam at about 40 psi into heated asphalt cement at about 25 psi through a specially designed and properly adjusted nozzle. The reduced viscosity and the increased volume and surface energy in the foamed asphalt allowed intimate coating and mixing of cold, wet aggregates or soils. Through the use of asphalt cements in a foamed state, materials normally considered unsuitable could be used in the preparation of mixes for stabilized bases and surfaces for low traffic road construction. By attaching the desired number of foam nozzles, the foamed asphalt can be used in conjunction with any type of mixing plant, either stationary or mobile, batch or continuous, central plant or in-place soil stabilization.