Effects of Special Aggregate on Bridge Deck Overlay Frictional Properties, HR-205, 1986

The Iowa DOT has been using the "Iowa Method" thin bonded low-slump dense Portland Cement Concrete (PCC) bridge deck overlay for rehabilitation of delaminated decks since 1963. In time, continued use of studded tires will wear away the transverse grooved texture. The objective of this research was to evaluate the benefit of incorporating a hard durable aggregate into a dense PCC overlay to provide frictional property longevity. The project included three overlays on I-35 near Ankeny. The texture and friction properties of two overlays, one constructed with crushed granite and the other with crushed quartzite coarse aggregate, were compared to an overlay constructed with locally available crushed limestone. There were no construction problems resulting from the use of crushed granite or quartzite. There was no significant frictional property benefit from the crushed granite or crushed quartzite through six years.

The Relationship of Ferroan Dolomite Aggregate to Rapid Concrete Deterioration, HR-266, 1987

Some of Iowa's 13,200 miles of portland cement concrete (pcc) pavement have remained structurally sound for over 50 years while others have suffered premature deterioration. Research has shown that the type of coarse aggregate used in the pcc is the major cause of this premature deterioration. Some coarse aggregates for concrete exhibit a nonuniform performance history. They contribute to premature deterioration on heavily salted primary roadways while providing long maintenance-free life on unsalted secondary pavements. This inconsistency supports the premise that there are at least two mechanisms that contribute to the deterioration. Previous research has shown that one of these mechanisms is a bad pore system. The other is apparently a chemical reaction. The objective of this research is to develop simple rapid test methods to predict the durability of carbonate aggregate in pcc pavement. X-ray diffraction analyses of aggregate samples have been conducted on various beds from numerous quarries producing diffraction plots for more than 200 samples of dolomitic or dolomite aggregates. The crystalline structures of these dolomitic aggregates show maximum-intensity dolomite/ankerite peaks ranging from a d-spacing of 2.884 angstroms for good aggregates to a d-spacing of 2.914 angstroms for nondurable aggregates. If coarse aggregates with known bad pore systems are removed from this summary, the d-spacing values of the remaining aggregates correlate very well with expected service life. This may indicate that the iron substitution for magnesium in the dolomite crystal is associated with the instability of the ferroan dolomite aggregates in pcc pavement.

Evaluation of Recycled Rubber in Asphalt Cement Concrete - Field Testing, Final Report for HR-330, 330A, 330B, 330C, 330D, 2002

Roughly 242 million used tires are generated annually in the United States. Many of these tires end up being landfilled or stockpiled. The stockpiles are unsightly, unsanitary, and also collect water which creates the perfect breeding ground for mosquitoes, some of which carry disease. In an effort to reduce the number of used tire stockpiles the federal government mandated the use of recycled rubber in federally funded, state implemented department of transportation (DOT) projects. This mandate required the use of recycled rubber in 5% of the asphalt cement concrete (ACC) tonnage used in federally funded projects in 1994, increasing that amount by 5% each year until 20% was reached, and remaining at 20% thereafter. The mandate was removed as part of the appropriations process in 1994, after the projects in this research had been completed. This report covers five separate projects that were constructed by the Iowa Department Of Transportation (DOT) in 1991 and 1992. These projects had all had some form of rubber incorporated into their construction and were evaluated for 5 years. The conclusion of the study is that the pavements with tire rubber added performed essentially the same as conventional ACC pavement. An exception was the use of rubber chips in a surface lift. This performed better at crack control and worse with friction values than conventional ACC. The cost of the pavement with rubber additive was significantly higher. As a result, the benefits do not outweigh the costs of using this recycled rubber process in pavements in Iowa.

Investigation of Rapid Thermal Analysis Procedures for Prediction of the Service Life of PCCP Carbonate Coarse Aggregate, HR-337, 1993

The major objective of this research project was to use thermal analysis techniques in conjunction with x-ray analysis methods to identify and explain chemical reactions that promote aggregate related deterioration in portland cement concrete. Twenty-two different carbonate aggregate samples were subjected to a chemical testing scheme that included: • bulk chemistry (major, minor and selected trace elements) • bulk mineralogy (minor phases concentrated by acid extraction) • solid-solution in the major carbonate phases • crystallite size determinations for the major carbonate phases • a salt treatment study to evaluate the impact of deicer salts Test results from these different studies were then compared to information that had been obtained using thermogravimetric analysis techniques. Since many of the limestones and dolomites that were used in the study had extensive field service records it was possible to correlate many of the variables with service life. The results of this study have indicated that thermogravimetric analysis can play an important role in categorizing carbonate aggregates. In fact, with modern automated thermal analysis systems it should be possible to utilize such methods on a quality control basis. Strong correlations were found between several of the variables that were monitored in this study. In fact, several of the variables exhibited significant correlations to concrete service life. When the full data set was utilized (n = 18), the significant correlations to service life can be summarized as follows ( a = 5% level): • Correlation coefficient, r, = -0.73 for premature TG loss versus service life. • Correlation coefficient, r, = 0.74 for relative crystallite size versus service life. • Correlation coefficient, r, = 0.53 for ASTM C666 durability factor versus service life. • Correlation coefficient, r, = -0.52 for acid-insoluble residue versus service life. Separation of the carbonate aggregates into their mineralogical categories (i.e., calcites and dolomites) tended to increase the correlation coefficients for some specific variables (r sometimes approached 0.90); however, the reliability of such correlations was questionable because of the small number of samples that were present in this study.

Recycling of Asphalt Concrete From I-80 in Cass County, HR-1011, 1978

Approximately 40,000 tons of deteriorated asphalt concrete has been removed from Interstate 80 in Cass County and stockpiled. Laboratory tests indicate that this material has considerable value when upgraded with new aggregate and asphalt cement. This report documents the procedures used and results obtained on an experimental recycling project. It was demonstrated that present drum mixing-recycling equipment and procedures can be used to utilize this material with satisfactory results. Laboratory analyses of material components and mixtures were performed; these analyses indicate mixture can be produced that is uniform, stable, and very closely resembles mixture produced with all virgin material. A 1700 foot long test section was constructed on US 169 in Kossuth County wherein salvaged asphalt concrete from I-80 in Cass County was utilized. The salvaged mix was blended with virgin aggregate and recycled through a modified drum mixing plant, the reprocessed mixture was satisfactorily placed 1 1/2 inches thick as a resurfacing course on an old PCC pavement. An inspection of the test section was made in December of 1978 to evaluate the performance after one full year of service. There was no evidence of rutting or shoving from traffic. The surface does, however, have a very dry and somewhat ravelled appearance. This can be related to a low asphalt content in the mix and some temperature control problems which were difficult to get fully corrected on such a short project and with a short supply of readily available materials.

Factors Relating to Aggregate Durability in Portland Cement Concrete, HR-2022, Interim Report, 1983

Over the past several years we conducted a comprehensive study on the pore systems of limestones used as coarse aggregate in portland cement concrete (pee) and their relationship to freeze-thaw aggregate failure. A simple test called the Iowa Pore Index Test was developed and used to identify those coarse aggregates that had freeze-thaw susceptible pore systems. Basically, it identified those aggregates that could take on a considerable amount of water but only at a slow rate. The assumption was that if an aggregate would take on a considerable amount of water at a slow rate, its pore system would impede the outward movement of water through a critically saturated particle during freezing, causing particle fracture. The test was quite successful when used to identify aggregates containing susceptible pore systems if the aggregates were clean carbonates containing less than 2% or 3% insolubles. The correlation between service record, ASTM C666B and the pore index test was good, but not good enough. It became apparent over the past year that there were factors other than the pore system that could cause an aggregate to fail when used in pee. The role that silica and clay play in aggregate durability was studied.

Penetration Characteristics of Asphalt in a Recycled Mixture, MLR-79-03, 1979

Samples of both recycled and nonrecycled asphaltic concrete were extracted in increments by the Abson Recovery Method and the penetration of the asphalt from each increment determined. The recycled projects were plantsite operations containing various amounts of virgin gravel. Cored samples were taken from the pavements on Kossuth County roads that were constructed as recycled projects in 1975, 1976, and 1977. Cored samples were also taken from a Kossuth County paving project done in 1975, that was not recycled. Comparison mix samples from 1978 construction projects in Marshall and Woodbury Counties of non - recycled projects are included. The test data from the penetrations of the recovered asphalt indicates that mixing of the old and new asphalt occurs very extensively in the hot recycling process. In laboratory controlled conditions it is difficult to coat aggregates with different penetration asphalts and prevent them from mixing.

Special Report on Alkali-Aggregate Reactivity in Iowa, MLR-80-03, 1980

The purpose of this investigation was to obtain information relative to the alkali-silica reaction in Iowa aggregates. Of particular concern were those aggregates in southwestern Iowa thought to be potentially alkali reactive. Further, should those aggregates have proven to be alkali-reactive, at what cement alkali content could these aggregates be considered to be deleteriously reactive? If the aggregates were proven to be reactive, what types of effects might show up in a structure in which an alkali-silica reaction has occurred? Also, what environmental conditions would cause the reaction? Finally, based on the information obtained from the investigation, would it be possible to raise the cement alkali content specifications? Would the Iowa DOT eliminate the alkali content limits altogether except for cement used with reactive aggregate in the same manner as AASHTO or ASTM? Also, would there be any other side effects that might occur as the result of using high alkali-cement?

Sieve Analysis of Combined Aggregate Samples by Different Test Methods, MLR-84-05, 1982

This past winter the sieve analysis of combined aggregate was investigated. This study was given No. 26 by the Central Laboratory. The purpose of this work was to try and develop a sieve analysis procedure for combined aggregate which is less time consuming and has the same accuracy as the method described in I.M. 304. In an attempt to use a variety of aggregates for this investigation, a request was made to each District Materials Office to obtain at least 3 different combined aggregate samples in their respective districts. At the same time it was also requested that the field technician test these samples, prior to submitting them to the Central Laboratory. The field technician was instructed to test each sample as described in method I.M. 304 and also by a modified AASHTO T27 method which will be identified in the report as Method A. The modified AASHTO Method A was identical to T27 with the exception that a smaller sample is used for testing. The field technicians submitted the samples, test results and also comments regarding the modified AASHTO procedure. The general comments of the modified AASHTO procedure were: The method was much simpler to follow; however, it took about the same amount of time so there was no real advantage. After reviewing AASHTO T27, T164, I.M. 304 and Report No. FHWA-RD-77-53 another test method was purposed. Report No. FHWA-RD-77-53 is a report prepared by FHWA from data they gathered concerning control practices and shortcut or alternative test methods for aggregate gradation. A second test method was developed which also was very similar to AASHTO T27, The test procedure for this method is attached and is identified as Method B. The following is a summary of test results submitted by the Field Technicians and obtained by the aggregate section of the Central Laboratory.

Evaluation of Asphalt Mixes Made from Reclaimed Concrete Aggregates, MLR-85-07, 1986

Three comparable hot mixed asphalt paving mixes were produced using two different aggregates produced from reclaimed portland cement concrete paving and one from a crushed limestone aggregate. These were subjected both dry and soaked to indirect tensile tests to determine the wet strength retention. One mix made from reclaimed concrete demonstrated a slightly better strength retention than the limestone mix and the other less. Satisfactory asphalt paving mixes can be produced from reclaimed concrete pavements but the increased asphalt demand (about 1%) negates part of the potential savings.

Performance of Poly-Carb, Inc. Flexogrid Bridge Overlay System, MLR-86-04, 2001

Intrusion of deicing materials and surface water into concrete bridge decks is a main contributor in deck reinforcing steel corrosion and concrete delamination. Salt, spread on bridge decks to melt ice, dissolves in water and permeates voids in the concrete deck. When the chloride content of the concrete in contact with reinforcing steel reaches a high enough concentration, the steel oxidizes. In Iowa, the method used to reduce bridge deck chloride penetration is the application of a low slump dense concrete overlay after the completion of all Class A and Class B floor repairs. A possible alternative to the use of dense concrete overlays, developed by Poly-Carb, Inc., is the MARK-163 FLEXOGRID Overlay System. FLEXOGRID is a two component system of epoxy and urethane which is applied on a bridge deck to a minimum thickness of ¼ inch. An aggregate mixture of silica quartz and aluminum oxide is broadcast onto the epoxy at a prescribed rate to provide deck protection and superior friction properties. The material is mixed on site and applied to the deck in a series of lifts (usually two) until the desired overlay thickness has been attained.

Effect of Compaction on the Aggregate Fracturing of Asphalt Concrete, MLR-86-07, 1986

Other states have elected not to adopt the 75 Blow Marshall Mix Design for their heavy traffic roads. Their reasons are that the 75 blow design cracks the larger aggregates. Therefore, a limited study was done during December, 1985, to try to determine what amount of cracking took place, and in what condition the cracks are in the mix.

Evaluation of Long-Term Field Performance of Cold In-Place Recycled Roads: Field and Laboratory Testing, TR-502, 2007

Cold in-place recycling (CIR) has become an attractive method for rehabilitating asphalt roads that have good subgrade support and are suffering distress related to non-structural aging and cracking of the pavement layer. Although CIR is widely used, its use could be expanded if its performance were more predictable. Transportation officials have observed roads that were recycled under similar circumstances perform very differently for no clear reason. Moreover, a rational mix design has not yet been developed, design assumptions regarding the structural support of the CIR layer remain empirical and conservative, and there is no clear understanding of the cause-effect relationships between the choices made during the design/construction process and the resulting performance. The objective of this project is to investigate these relationships, especially concerning the age of the recycled pavement, cumulative traffic volume, support conditions, aged engineering properties of the CIR materials, and road performance. Twenty-four CIR asphalt roads constructed in Iowa from 1986 to 2004 were studied: 18 were selected from a sample of roads studied in a previous research project (HR-392), and 6 were selected from newer CIR projects constructed after 1999. This report describes the results of comprehensive field and laboratory testing for these CIR asphalt roads. The results indicate that the modulus of the CIR layer and the air voids of the CIR asphalt binder were the most important factors affecting CIR pavement performance for high-traffic roads. For low-traffic roads, the wet indirect tensile strength significantly affected pavement performance. The results of this research can help identify changes that should be made with regard to design, material selection, and construction in order to improve the performance and cost-effectiveness of future recycled roads.

Evaluation of Long-Term Field Performance of Cold In-Place Recycled Roads: Summary Report, TR-502, 2007

Cold in-place recycling (CIR) has become an attractive method for rehabilitating asphalt roads that have good subgrade support and are suffering distress related to non-structural aging and cracking of the pavement layer. Although CIR is widely used, its use could be expanded if its performance were more predictable. Transportation officials have observed roads that were recycled under similar circumstances perform very differently for no clear reason. Moreover, a rational mix design has not yet been developed, design assumptions regarding the structural support of the CIR layer remain empirical and conservative, and there is no clear understanding of the cause-effect relationships between the choices made during the design/construction process and the resulting performance. The objective of this project is to investigate these relationships, especially concerning the age of the recycled pavement, cumulative traffic volume, support conditions, aged engineering properties of the CIR materials, and road performance. Twenty-four CIR asphalt roads constructed in Iowa from 1986 to 2004 were studied: 18 were selected from a sample of roads studied in a previous research project (HR-392), and 6 were selected from newer CIR projects constructed after 1999. This report summarizes the results of a comprehensive program of field distress surveys, field testing, and laboratory testing for these CIR asphalt roads. The results of this research can help identify changes that should be made with regard to design, material selection, and construction in order to lengthen the time between rehabilitation cycles and improve the performance and cost-effectiveness of future recycled roads.

Performance Evaluation of Concrete Pavement Granular Subbase - Pavement Surface Condition Evaluation, TR-554, 2008

This research project covered a wide range of activities that allowed researchers to understand the relationship between stability, pavement distress, and recycled portland cement concrete (RPCC) subbase aggregate materials. Detailed laboratory and field tests, including pavement distress surveys, were conducted at 26 sites in Iowa. Findings show that specific gravities of RPCC are lower than those of crushed limestone. RPCC aggregate material varies from poorly or well-graded sand to gravel. A modified Micro-Deval test procedure showed that abrasion losses of virgin aggregate materials were within the maximum Micro-Deval abrasion loss of 30% recommended by ASTM D6028-06. Micro-Deval abrasion loss of RPCC aggregate materials, however, was much higher than that of virgin materials and exceeded 30% loss. Modulus of elasticity of RPCC subbase materials is high but variable. RPCC subbase layers normally have low permeability. The pavement surfaces for both virgin and RPCC subbase across Iowa were evaluated to fulfill the objectives of this study related to field evaluation. Visual distress surveys were conducted to gather the detailed current pavement condition information including the type, extent, and severity of the pavement distresses. The historical pavement condition information for the surveyed field sections was extracted from the Iowa DOT's Pavement Management Information System (PMIS). The current surface condition of existing field pavements with RPCC subbase was compared with the virgin aggregate subbase sections using two different approaches. The changes in pavement condition indices (PCI and IRI) with time for both types of pavements (subbases) were compared.