Relationship of Carbonate Aggregates to Concrete Aging, HR-116, 1967

HR-116 is concerned with the relationship of carbonate aggregate to aging of highway concrete. The ultimate purpose of the research is to provide the Materials Department with better criteria for selection of carbonate aggregates for use in highway concrete. The research stems from the problem in Iowa which relates durability of highway concrete to use of certain aggregates. Service records of certain highways have shown that concrete deterioration is related to the source of coarse carbonate aggregate. Research on this problem in projects HR-15 and HR-86 helped define three broad areas of the problem in more detail: 1. The problem of evaluation of rocks which pass current specifications but have poor service records 2. The basic problem of how rocks contribute to distress in concrete 3. The problem of how concrete ages or weathers.

Effects of Cement on Moisture Migration in Concrete, Phase A, Laboratory Study of Moisture Migration in Hardened Cement Paste, HR-141, 1972

The Columbus Laboratories of Battelle Memorial Institute is currently conducting a study of the effect of cement on moisture migration in concrete as related to the problem of D-cracking of portland cement concrete pavements. The study began on December 31, 1970, and is planned as a 3-year program. The work plan, approved by the policy committee of the members of the Iowa, Kansas, and Missouri highway departments and the Federal Highway Administration, is composed of four parts. The first phase (A) of the investigation concerned the movement of moisture into and from hardened cement pastes and the dimensional changes accompanying the moisture changes. Small slab specimens of hardened neat cement pastes were prepared from 32 different cements which were prepared at the same water/cement ratio and hydrated to the same maturity factor.

Detection of Steel Corrosion in Bridge Decks and Reinforced Concrete Pavement, HR-156, 1977

The Iowa Department of Transportation initiated this research to evaluate the reliability, benefit and application of the corrosion detection device. Through field testing prior to repair projects and inspection at the time of repair, the device was shown to be reliable. With the reliability established, twelve additional devices were purchased so that this evaluation procedure could be used routinely on all repair projects. The corrosion detection device was established as a means for determining concrete removal for repair. Removal of the concrete down to the top reinforcing steel is required for all areas exhibiting electrical potentials greater than 0.45 Volt. It was determined that the corrosion detection device was not applicable to membrane testing. The corrosion detection device has been used to evaluate corrosion of reinforcing steel in continuously reinforced concrete pavement.

Evaluation of Gap-Graded Asphalt Concrete Mixtures, Vol. 1. Physical Properties (Part I: Mechanical Properties), HR-157, Volume 1, 1972 (1973)

This report presents the results of a comparative laboratory study between well- and gap-graded aggregates used in asphalt concrete paving mixtures. A total of 424 batches of asphalt concrete mixtures and 3,960 Marshall and Hveem specimens were examined. There is strong evidence from this investigation that, with proper-combinations of aggregates and asphalts, both continuous- and gap-graded aggregates can produce mixtures of high density and of qualities meeting current design criteria. There is also reason to believe that the unqualified acceptance of some supposedly desirable, constant, mathematical relationship between adjacent particle sizes of the form such as Fuller's curve p = 100(d/D)^n is not justified. It is recommended that the aggregate grading limits be relaxed or eliminated and that the acceptance or rejection of an aggregate for use in asphalt pavement be based on individual mixture evaluation. Furthermore, because of the potential attractiveness of gap-graded asphalt concrete in cost, quality, and skid and wear resistance, selected gap-graded mixtures are recommended for further tests both in the laboratory and in the field, especially in regard to ease of compaction and skid and wear resistance.

Prevention of Reflection Cracking in Asphalt Overlays with Structofors, Petromate, and Cerex, HR-158, 1977

This report presents construction methods and results using three reinforcing fabrics to prevent reflection cracking in an asphalt overlay. The original highway in the rural area was Portland Cement Concrete 20 feet wide. It was widened by adding 2 feet of asphaltic concrete 10 inches deep on each side prior to resurfacing. Data are presented for the widening joint and transverse cracks in the rural area and for the random cracking in the urban area.

A Fifteen Year Performance Summary of Fibrous PC Concrete Overlay Research in Greene County, Iowa, HR-165, 1989

The Greene County, Iowa, overlay project, completed in October 1973, was evaluated in October 1978, after five years in October 1983, after ten years and most recently in October 1988 after fifteen years of service. The 33 fibrous concrete sections, four CRCP sections, two mesh reinforced and two plain concrete sections with doweled reinforcement were rated relative to each other on a scale of 0 to 100. The rating was conducted by original members of the Project Planning Committee, Iowa DOT, Iowa County, Federal Highway Administration and industry representatives. In all, there were 23, 25 and 17 representatives who rated the project in 1978, 1983 and 1988 respectively. The 23, 25 or 17 values were then averaged to provide a final rating number for each section or variable. All experimental overlay sections had performed quite well in the period from five through 15 years, experiencing only limited additional deterioration.

Crack Survey for Fibrous P.C. Concrete Overlay Research in Greene County, Iowa, HR-165, 1979

The three miles of fibrous concrete resurfacing in Greene County, Iowa were placed in September and early October, 1973. It was recognized in advance that cracking and other performance characteristics of the fibrous concrete sections and of the control sections would be major factors in the evaluation of the project. A low level aerial survey was made of the old pavement. During construction of the resurfacing, the aerial survey was checked to insure that cracks in the old pavement were referenced to the 100 ft. station marks placed in the resurfacing. A final report for research project HR-165, based upon overall performance evaluation was published in December 1978.

Fibrous Concrete Resurfacing Greene County, Iowa, HR-165, 1976

The three miles of fibrous concrete resurfacing in Greene County, Iowa were placed in September and early October, 1973. It was recognized in advance that cracking and other performance characteristics of the fibrous concrete sections and of the control sections would be major factors in the evaluation of the project. A low level aerial survey was made of the old pavement. During construction of the resurfacing, the aerial survey was checked to insure that cracks in the old pavement were referenced to the 100 ft. station marks placed in the resurfacing. Crack surveys have been conducted on dates indicated below. Additional cracks found at each subsequent survey are shown in a color matching the date notation. April, 1974 November, 1974 October, 1975 October, 1976

Fibrous Concrete Resurfacing Greene County, Iowa, HR-165, 1977

The three miles of fibrous concrete resurfacing in Greene County, Iowa were placed in September and early October, 1973. It was recognized in advance that cracking and other performance characteristics of the fibrous concrete sections and of the control sections would be major factors in the evaluation of the project. A low level aerial survey was made of the old pavement. During construction of the resurfacing, the aerial survey was checked to insure that cracks in the old pavement were referenced to the 100 ft. station marks placed in the resurfacing. Crack surveys have been conducted on dates indicated below. Additional cracks found at each subsequent survey are shown in a color matching the date notation. April, 1974 November, 1974 October, 1975 October, 1976 October, 1977

Survey No. 1, Fibrous Concrete Resurfacing Greene County, Iowa, HR-165, 1974

The three miles of fibrous concrete resurfacing in Greene County, Iowa were placed in September and early October, 1973. It was recognized in advance that cracking and other performance characteristics of the fibrous concrete sections and of the central sections would be major factors in the evaluation of the project. A low level aerial survey was made of the old pavement. During construction of the resurfacing, the aerial survey was checked to insure that cracks in the old pavement were referenced to the 100 ft. station marks placed in the resurfacing. The crack survey recorded herein was made in March and April, 1974. Those cracks in the resurfacing that are reflections of cracks in the underlying slab are identified by /\ marks. Observations (not detailed crack surveys) made in June, 1974 indicate that further cracking of the resurfacing has occurred since this report was prepared. In particular, there appears to be same additional longitudinal cracking over the widening joints.

A Ten Year Performance Summary of Fibrous PC Concrete Overlay Research in Greene County, Iowa, HR-165, 1984

The Greene County, Iowa, overlay project, completed in October, 1973, was evaluated in October, 1978, after five years of service and most recently in October, 1983, after ten years of service. The 33 fibrous concrete sections, four CRCP sections, two mesh reinforced and two plain concrete sections with doweled reinforcement were rated relative to each other on a scale of 0 to 100. The rating was conducted by original members of the Project Planning Committee, Iowa DOT, Iowa County, Federal Highway Administration, University of Illinois and industry representatives. In all, there were 23 and 24 representatives who rated the project in 1978 and 1983 respectively. The 23 or 24 values were then averaged to provide a final rating number for each section or variable. All experimental overlay sections had performed quite well in the period from five through 10 years, experiencing only limited additional deterioration. Based upon this relatively good performance through 10 years, the sections will be maintained for further research with another evaluation at 15 years. The 4" thick nonfibrous mesh reinforced continuous reinforced concrete pavement overlay sections provided the best performance in this research project. Another nonfibrous 5" thick bar reinforced overlay section performed almost as well. The best performance of a fibrous reinforced concrete section was obtained with 160 pounds of fiber per cubic yard.

Transverse Joint Sealing with Various Sealants, HR-203, 1983

Iowa's first portland cement concrete pavement was constructed in 1904 in the City of LeMars. A portion of that pavement served traffic until 1974 at which time it was resurfaced. The first rural Iowa pee pavement (16' wide, 6" to 7" thick) was constructed under the direction of the Iowa State Highway Commission in 1913. Some of Iowa's early pavements had transverse joints at 25-foot spacings. At that time, joint spacings across the nation ranged from 24 to 100 ft. There have been many changes in joint design over the years with some pavements being constructed without transverse joints. Joint spacing on Iowa primary pavements has generally remained around 20 feet with this spacing having been adopted as an Iowa standard in 1954. Until 1978 it was common to specify a 40-foot joint spacing on secondary pavements. The performance of the pavements with joint spacings greater than 20 feet, and in some cases no contraction joints, generated a 1955 research project on joint spacing. This project was 16 miles long containing sections without contraction joints and sections with joints sawed at intervals of 20, 50 and 80 feet. Approximately half of the sawed joints were left unsealed. The results of this research supported the 20-foot spacing, but were inconclusive regarding the benefits of sealing. One of the desired characteristics of joint sealing material is that it should act as a moisture barrier and prevent the intrusion of surface water. It was generally accepted from past experience that the hot poured type joint seals did not provide this effective moisture barrier.

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.

Detection of Concrete Delamination by Infrared Thermography, HR-244, 1986

Iowa has approximately 1000 bridges that have been overlaid with a nominal 2" of portland cement concrete. A Delamtect survey of a sampling of the older overlaid bridges indicated delaminations in several of them. Eventually these bridges as well as those that have not received an overlay must be programmed for rehabilitation. Prior to rehabilitation the areas which are delaminated must be identified. There are currently two standard methods of determining delaminated areas in bridge decks; sounding with a metal object or a chain drag and sounding with an electro-mechanical sounding system (Delamtect). Sounding with a metal object or chain drag is time consuming and the accuracy is dependent on the ear of the operator and may be affected by traffic noise. The Delamtect requires less field time but the graphical traces require that data reduction be done in the office. A recently developed method of detecting delamination is infrared thermography. This method is based on the temperature difference between sound and delaminated concrete. A contract was negotiated with Donohue and Associates, Inc. of Sheboygan, Wisconsin, to survey 18 p.c. concrete overlaid bridge decks in Iowa using the infrared thermography method of detecting delaminations.

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.