An Investigation of Emulsion Stabilized Limestone Screenings, HR-309, 1994

A significant amount of waste limestone screenings is produced during aggregate production. This waste material cannot be used in highway construction because it does not meet current highway specifications. The purpose of this research was to determine if a waste limestone screenings/emulsion mix could be used to construct a base capable of supporting local traffic. A 1.27 mile (2.04 km) section of roadway in Linn County was selected for this research. The road was divided into seven sections. Six of the sections were used to test 4 in. (100 mm) and 6 in. (150 mm) compacted base thicknesses containing 2.5%, 3.5%, and 4.5% residual asphalt contents. The seventh section was a control section containing untreated waste limestone screenings. This research on emulsion stabilized limestone screenings supports the following conclusions: (1) A low maintenance roadway can be produced using a seal coat surface on 6 in. (150 mm) of stabilized limestone screenings with 4.5% asphalt cement; (2) A 6 in. (150 mm) emulsion stabilized base with less than 3.5% asphalt cement does not produce a satisfactory low cost maintenance roadway; (3) A 4 in. (100 mm) emulsion stabilized base does not produce a satisfactory low cost maintenance roadway; and (4) A 2 in. (50 mm) asphalt concrete surface would be necessary on many roads to provide a low maintenance roadway using emulsion stabilized limestone screenings.

Low Cost Fly Ash - Sand Stabilized Roadway Des Moines County, HR-259, 1991

The objectives of this research were to develop a low cost fly ash-sand stabilized roadway and to correlate field performance with pavement design assumptions on a county road heavily trafficked by trucks hauling grain. The road was constructed during the summer of 1984. Three test sections comprised of different base thicknesses were incorporated in the roadway and were tested for compressive stength, structural rating, and rut depth. Annual crack surveys showed no appreciable difference in transverse cracking between the test sections and little to no rutting. The sandbase drainage characteristics beneath the roadway may have contributed to the satisfactory performance of the test sections. This project indicates that in spite of the inflated cost of construction due to the research nature of the work, a fly ash-sand base can be a viable alternative for roadway stabilization.

Studies on Soil-Aggregate-Sodium Chloride Stabilized Roads in Franklin County, Iowa, HR-33

This investigation was conducted to study the performance characteristics of low cost roadway surfaces of soil-aggregate-sodium chloride mixtures. Many roads have been successfully stabilized with sodium chloride. However, little information is available on either the properties of the road materials or the effects of sodium chloride on the materials. The performance of some of the sodium chloride stabilized roads in Franklin County, Iowa, and the performance of some near-by nonchemically treated roads has been studied. The study of sodium chloride stabilized roads was restricted to the roads in which the binder soil used in construction came from the same source. The effects of sodium chloride on some of the engineering properties of the soil and soil-aggregate mixtures used were studied in the laboratory.

An Investigation of Emulsion Stabilized Limestone Screenings, HR-309, 1989

During the processing of limestone to produce commercial aggregates, a significant amount of waste limestone screenings is produced. This waste material cannot be used in highway construction because it does not meet current highway specifications. The purpose of this research was to determine if a waste limestone screenings/emulsion mix could be used to construct a base capable of supporting local traffic. A 1.27 mile section of roadway in Linn County was selected for this research. The road was divided into seven sections. Six of the sections were used to test 4" and 6" compacted base thicknesses containing 2.5%, 3.5%, and 4.5% residual asphalt contents. The seventh section was a control section containing untreated waste limestone screenings.

Design and Construction Procedures for Concrete Overlay and Widening of Existing Pavements, September 2005

State Highway Departments and local street and road agencies are currently faced with aging highway systems and a need to extend the life of some of the pavements. The agency engineer should have the opportunity to explore the use of multiple surface types in the selection of a preferred rehabilitation strategy. This study was designed to look at the portland cement concrete overlay alternative and especially the design of overlays for existing composite (portland cement and asphaltic cement concrete) pavements. Existing design procedures for portland cement concrete overlays deal primarily with an existing asphaltic concrete pavement with an underlying granular base or stabilized base. This study reviewed those design methods and moved to the development of a design for overlays of composite pavements. It deals directly with existing portland cement concrete pavements that have been overlaid with successive asphaltic concrete overlays and are in need of another overlay due to poor performance of the existing surface. The results of this study provide the engineer with a way to use existing deflection technology coupled with materials testing and a combination of existing overlay design methods to determine the design thickness of the portland cement concrete overlay. The design methodology provides guidance for the engineer, from the evaluation of the existing pavement condition through the construction of the overlay. It also provides a structural analysis of various joint and widening patterns on the performance of such designs. This work provides the engineer with a portland cement concrete overlay solution to composite pavements or conventional asphaltic concrete pavements that are in need of surface rehabilitation.

Final Report for Research Project HR-181, Macadam Base Shoulders, September 1981

Highway safety and pavement performance can be directly influenced by the type of shoulders that are constructed. Shoulder design alternatives have always been rather limited. Moreover, the use of some of the alternatives has always been restricted by funding limitations. This research project seeks to explore the use of modified macadam base construction for shoulders. This type of shoulder design could offer the designer another option when paved or stabilized shoulders are being considered. Macadam base construction has in the past been shown to be quite strong and free draining. Two macadam base shoulder designs were developed and constructed for this research project. A new roadway embankment and P.C.C. pavement were constructed on a section of US 6 east of Adel in Dallas County. The macadam base shoulders were constructed adjacent to the pavement as part of the project. The north shoulder was finished with a choke stone course and bituminous surface treatment and the south shoulder was finished with a two (2) inch layer of Type B Class I1 asphalt concrete. Macadam stone base shoulders can be built with relatively minor construction problems with comparable strength and less cost than asphalt treated base shoulders. The macadam stone base shoulders have performed well with very little maintenance necessary. The improved drainage substantially reduces deterioration of the pavement joints.

Optimization of Soil Stabilization with Class C Fly Ash, January 1987

Previous Iowa DOT sponsored research has shown that some Class C fly ashes are ementitious (because calcium is combined as calcium aluminates) while other Class C ashes containing similar amounts of elemental calcium are not (1). Fly ashes from modern power plants in Iowa contain significant amounts of calcium in their glassy phases, regardless of their cementitious properties. The present research was based on these findings and on the hyphothesis that: attack of the amorphous phase of high calcium fly ash could be initiated with trace additives, thus making calcium available for formation of useful calcium-silicate cements. Phase I research was devoted to finding potential additives through a screening process; the likely chemicals were tested with fly ashes representative of the cementitious and non-cementitious ashes available in the state. Ammonium phosphate, a fertilizer, was found to produce 3,600 psi cement with cementitious Neal #4 fly ash; this strength is roughly equivalent to that of portland cement, but at about one-third the cost. Neal #2 fly ash, a slightly cementitious Class C, was found to respond best with ammonium nitrate; through the additive, a near-zero strength material was transformed into a 1,200 psi cement. The second research phase was directed to optimimizing trace additive concentrations, defining the behavior of the resulting cements, evaluating more comprehensively the fly ashes available in Iowa, and explaining the cement formation mechanisms of the most promising trace additives. X-ray diffraction data demonstrate that both amorphous and crystalline hydrates of chemically enhanced fly ash differ from those of unaltered fly ash hydrates. Calciumaluminum- silicate hydrates were formed, rather than the expected (and hypothesized) calcium-silicate hydrates. These new reaction products explain the observed strength enhancement. The final phase concentrated on laboratory application of the chemically-enhanced fly ash cements to road base stabilization. Emphasis was placed on use of marginal aggregates, such as limestone crusher fines and unprocessed blow sand. The nature of the chemically modified fly ash cements led to an evaluation of fine grained soil stabilization where a wide range of materials, defined by plasticity index, could be stabilized. Parameters used for evaluation included strength, compaction requirements, set time, and frost resistance.

Estimating Design-Flood Discharges for Streams in Iowa Using Drainage-Basin and Channel-Geometry Characteristics, HR-322, 1993

Drainage-basin and channel-geometry multiple-regression equations are presented for estimating design-flood discharges having recurrence intervals of 2, 5, 10, 25, 50, and 100 years at stream sites on rural, unregulated streams in Iowa. Design-flood discharge estimates determined by Pearson Type-III analyses using data collected through the 1990 water year are reported for the 188 streamflow-gaging stations used in either the drainage-basin or channel-geometry regression analyses. Ordinary least-squares multiple-regression techniques were used to identify selected drainage-basin and channel-geometry regions. Weighted least-squares multiple-regression techniques, which account for differences in the variance of flows at different gaging stations and for variable lengths in station records, were used to estimate the regression parameters. Statewide drainage-basin equations were developed from analyses of 164 streamflow-gaging stations. Drainage-basin characteristics were quantified using a geographic-information-system (GIS) procedure to process topographic maps and digital cartographic data. The significant characteristics identified for the drainage-basin equations included contributing drainage area, relative relief, drainage frequency, and 2-year, 24-hour precipitation intensity. The average standard errors of prediction for the drainage-basin equations ranged from 38.6% to 50.2%. The GIS procedure expanded the capability to quantitatively relate drainage-basin characteristics to the magnitude and frequency of floods for stream sites in Iowa and provides a flood-estimation method that is independent of hydrologic regionalization. Statewide and regional channel-geometry regression equations were developed from analyses of 157 streamflow-gaging stations. Channel-geometry characteristics were measured on site and on topographic maps. Statewide and regional channel-geometry regression equations that are dependent on whether a stream has been channelized were developed on the basis of bankfull and active-channel characteristics. The significant channel-geometry characteristics identified for the statewide and regional regression equations included bankfull width and bankfull depth for natural channels unaffected by channelization, and active-channel width for stabilized channels affected by channelization. The average standard errors of prediction ranged from 41.0% to 68.4% for the statewide channel-geometry equations and from 30.3% to 70.0% for the regional channel-geometry equations. Procedures provided for applying the drainage-basin and channel-geometry regression equations depend on whether the design-flood discharge estimate is for a site on an ungaged stream, an ungaged site on a gaged stream, or a gaged site. When both a drainage-basin and a channel-geometry regression-equation estimate are available for a stream site, a procedure is presented for determining a weighted average of the two flood estimates.

Iowa Workforce Development Annual Report Fiscal Year 2013

The past fiscal year brought some improvements in the Iowa economy that should position the state for stronger hiring in the year ahead. The housing market is on solid footing, and hiring is broader in scope, including a number of the service-providing industries that had been on hold for some time. State and local government fiscal conditions have also stabilized due to a rise in tax revenues. This means that government cutbacks will be less of a drag on overall job growth. During FY 2013, Iowa’s non-farm jobs advanced by 19,200 (+1.3 percent) compared to 23,000 (+1.6 percent) for the prior fiscal year. Although manufacturing continued to post the largest over the year job gain at close to 5,600, job growth shifted away from manufacturing to the service providing industries by mid-year. Annual job gains of 2,000 or more were reflected in professional and business services, education and health, leisure and hospitality, retail trade and financial activities. Statewide non-farm employment averaged 1,517,700 in FY 2013, the highest level achieved since the record of 1,524,800 in FY 2008.

Macadam Base Shoulders, HR-181, 1977

Highway safety and pavement performance can be directly influenced by the type of shoulders that are constructed. Shoulder design alternatives have always been rather limited. Moreover, the use of some of the alternatives has always been restricted by funding limitations. This research project seeks to explore the use of modified macadam base construction for shoulders. This type of shoulder design could offer the designer another option when paved or stabilized shoulders are being considered. Macadam base construction has in the past been shown to be quite strong and freedraining. Two macadam base shoulder designs were developed and constructed for this research project. A new roadway embankment and P.C.C. pavement were constructed on a section of US 6 east of Adel in Dallas County. The macadam base shoulders were constructed adjacent to the pavement as part of the project. The north shoulder was finished with a choke stone course and bituminous surface treatment and the south shoulder was finished with a two (2) inch layer of Type B Class II asphalt concrete. The initial results are considered satisfactory. Follow-up performance evaluation and load bearing tests are planned.

Performance of Randomly Oriented, Fiber-Reinforced Roadway Soils, HR-211, 1982

Several primary techniques have been developed through which soil aggregate road material properties may be improved. Such techniques basically involve a mechanism of creating a continuous matrix system of soil and/or aggregate particles, interlocked through the use of some additive such as portland cement, lime, or bituminous products. Details by which soils are stabilized vary greatly, but they are dependent on the type of stabilizing agent and nature of the soil, though the overall approach to stabilization has the common feature that improvement is achieved by some mechanism(s) forcing individual particles to adhere to one another. This process creates a more rigid material, most often capable of resisting the influx of water during freezing, loss of strength due to high moisture content and particle dispersion during thawing, and loss of strength due to migration of fines and/or water by capillarity and pumping. The study reported herein, took a new and relatively different approach to strengthening of soils, i.e., improvement of roadway soils and/or soil-aggregate materials by structural reinforcement with randomly oriented fibers. The purpose of the study was to conduct a laboratory and field investigation into the potential of improving (a) soil-aggregate surfaced and subgrade materials, including those that are frost-prone and/or highly moisture susceptible, and (b) localized base course materials, by uniting such materials through fibrous reinforcement. The envisioned objective of the project was the development of a simple construction technique(s) that could be (a) applied on a selective basis to specific areas having a history of poor performance, or (b) used for improvement of potential base materials prior to surfacing. Little background information on such purpose and objective was available. Though the envisioned process had similarities to fibrous reinforced concrete, and to fibrous reinforced resin composites, the process was devoid of a cementitious binder matrix and thus highly dependent on the cohesive and frictional interlocking processes of a soil and/or aggregate with the fibrous reinforcement; a condition not unlike the introduction of reinforcing bars into a concrete sand/aggregate mixture without benefit of portland cement. Thus the study was also directed to answering some fundamental questions: (1) would the technique work; (2) what type or types of fibers are effective; (3) are workable fibers commercially available; and (4) can such fibers be effectively incorporated with conventional construction equipment, and employed in practical field applications? The approach to obtaining answers to these questions, was guided by the philosophy that an understanding of basic fundamentals was essential to developing a body of engineering knowledge, that would serve as the basis for eventual development of design procedures with fibrous products for the applications previously noted.

Characteristics of Chemical Treated Roadway Surfaces, HR-33, 1963

Iowa Highway Commission Project HR-33, "Characteristics of Chemically Treated Roadway Surfaces", was investigated at the Iowa Engineering Experiment Station under Project 375-S. The purpose of the project as originally proposed was to study the physical and chemical characteristics of chemically treated roadway surfaces. All chemical treatments were to be included, but only sodium chloride and calcium chloride treated roadways were investigated. The uses of other types of chemical treatment were not discovered until recently, notably spent sulfite liquor and a commercial additive. Costs of stabilized secondary roads in Hamilton County averaged $4300.00 per mile even though remanent soil-aggregate material was used. The cost of similar roads in Franklin County was $4400.00 per mile. The Franklin County road surfaces were constructed entirely from materials that were hauled to the road site. Costs in Butler County were a little over $3000.00 per mile some eight years ago. Chemical investigations indicate that calcium chloride and sodium chloride are lost through leaching. Approximately 95 percent of the sodium chloride appears to have been lost, and nearly 65 percent of the calcium chloride has disappeared. The latter value may be much in error since surface dressings of calcium chloride are commonly used and have not been taken into account. Clay contents of the soil-aggregate-chemical stabilized roads range from about 6 to ll percent, averaging 8 or 9 percent. The thicknesses of stabilized mats are usually 2 to 4 inches, with in-place densities ranging from 130 to 145 pcf. Generally the densities found in sodium chloride stabilized roads were slightly higher than those found in the calcium chloride stabilized roads.

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.

Report on Fly Ash as a Soil Additive, MLR-81-03, 1981

The addition of a selected self-cementing, Class C fly ash to blow sand soils improves their compacted strength greatly as opposed to the minimal strength improvement when fly ash is mixed with loess soil. By varying the percentage of fly ash added, the resulting blow sand-fly ash mixture can function as a low strength stabilized material or as a higher strength sub-base. Low strength stabilized material can also be obtained by mixing loess soils with a selected Class C fly ash. The development of the higher strength values required for subbase materials is very dependent upon compaction delay time and moisture condition of the material. Results at this time indicate that, when compaction delays are involved, excess moisture in the material has the greatest positive effect in achieving minimum strengths. Other added retarding agents, such as borax and gypsum, have less effect.

Thin Maintenance Surfaces for Municipalities, TR-507, 2007

As streets age, officials must deal with rehabilitating and reconstructing these pavements to maintain a safe and comfortable ride. In light of nationwide budget shortfalls, cost-effective methods of extending pavement service life must be developed or the overall condition of street systems will continue to fall. Thin maintenance surfaces (TMSs) are a set of cost-effective preventive maintenance surfacing techniques that can be used to extend the life of bituminous pavement—pavement built with hot mix asphalt, hot mix asphalt overlays of portland cement concrete pavements, built-up seal coat (chip seal), stabilized materials, or a combination of these. While previous phases of TMS research have provided information about the uses of thin maintenance surfaces in rural settings, urban areas have different road maintenance challenges that should be considered separately. This research provides city street officials with suggestions for TMS techniques that street departments can easily test and include into their current programs. This research project facilitated the construction of TMS test sections in Cedar Rapids, Council Bluffs, and West Des Moines (all urban settings in Iowa). Test section sites and surfaces were selected to suit the needs of municipalities and were applied to roads with an array of various distresses and maintenance needs. Condition surveys of each test section were performed before construction, after construction, and after the first winter to record the amount and severity of existing distress and calculate the pavement condition index. Because conditions of the test sections varied greatly, determining which surface was most successful by comparing case studies was not feasible. However, some general conclusions can be made from this research. TMSs are suitable preventive maintenance techniques for a municipal street department’s program for preserving existing pavements. Careful attention should be paid to proper planning, quality control during construction, aggregate and binder selection, and aggregate embedment in order to support successful TMS application.