Recycling of Cass County I-80 Asphalt Concrete, Progress Report, HR-1011, 1977

Approximately 40,000 tons of slightly damaged asphalt concrete has been removed from Interstate 80 in Cass and stockpiled. Laboratory tests had indicated that this material had 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 new material. Follow~up evaluations will be made to determine the effects of traffic and environment. Preliminary data indicate that plans should be made to incorporate the stockpiled material in projects near the stockpile site.

Study of Type 'A' Asphaltic Concrete Surface Mix Design, R-232, 1968

In some asphaltic concrete mixes asphalt absorption in field mixes is difficult to predict by the routine mix design tests presently being used. Latent or slow absorption in hot mixes is hard to compensate for in field control due to aggregate gradations being near maximum density. If critical asphalt need could be changed by increasing voids in the mineral aggregate so that more freedom could be exercised in compensating for the absorption, this may aid in design. The voids in the mineral aggregate can be related to composite gradation of total aggregate in a mixture, i.e. if a composite gradation of aggregate is finer than that of maximum density curve, the V.M.A. will be greater than that of a mix of maximum density. The typical gradation of Iowa Type 'A' mixes is finer than a gradation which is near the centerline of the specification at sieves larger than the No. 30 and coarser at the lower sieve sizes. The mixes of the typical gradation will have higher V.M.A. than those of the near centerline mixes. By studying properties of the mixes of the typical gradation and comparing them with those of the mixes of maximum density, it may aid in the modification and simplification of our present testing methods and specification requirements while still maintaining control of quality of the mix by controlling voids, stability, gradation and asphalt content.

Fatigue Behavior of Air-Entrained Concrete, HR-183, 1977

When a material fails under a number of repeated loads, each smaller than the ultimate static strength, a fatigue failure is said to have taken place. Many studies have been made to characterize the fatigue behavior of various engineering materials. The results of some of these studies have proved invaluable in the evaluation and prediction of the fatigue strength of structural materials. Considerable time and effort has gone into the evaluation of the fatigue behavior of metals. These early studies were motivated by practical considerations: The first fatigue tests were performed on materials that had been observed to fail after repeated loading of a magnitude less than that required for failure under the application of a single load. Mine-hoist chains, railway axles, and steam engine parts were among the first structural components to be recognized as exhibiting fatigue behavior. Since concrete is usually subjected to static loading rather than cyclic loading, need for knowledge of the fatigue behavior of concrete has lagged behind that of metals. One notable exception to this, however, is in the area of highway and airfield pavement design. Due to the fact that the fatigue behavior of concrete must be understood in the design of pavements and reinforced concrete bridges, highway engineers have provided the motivation for concrete fatigue studies since the 1920's.

Bonded, Thin-Lift, Non-Reinforced Portland Cement Concrete Resurfacing, HR-191, 1980

A Research Project involving two, three, four and five inches of bonded Portland Cement Concrete Overlay on a 1.3 mile Portland Cement Concrete pavement was conducted in Clayton County, Iowa, during September, 1977, centering on the following objectives: 1. Determine the mixing and proportioning procedures required in using a conventional, central mix proportioning plant to produce a dense Portland Cement Concrete mixture using standard mixes with super-water reducing admixtures; 2. Determine the economics, longevity and maintenance performance of a bonded, thin-lift, non-reinforced Portland Cement Concrete resurfacing course using conventional procedures, equipment and concrete paving mixtures both with and without super-water reducing admixtures; 3. Determine if an adequate bond between the existing pavement and an overlay of thin-lift, dense, non-reinforced Portland Cement Concrete can be obtained with only special surface cleaning and no surface removal or grinding.

Fatigue Behavior of Air-Entrained Concrete: Phase II, HR-197, 1979

When a material fails under a number of repeated loads, each smaller than the ultimate static strength, a fatigue failure is said to have taken place. Many studies have been made to characterize the fatigue behavior of various engineering materials. The results of some of these studies have proved invaluable in the evaluation and prediction of the fatigue strength of structural materials. Considerable time and effort have gone into the evaluation of the fatigue behavior of metals. These early studies were motivated by practical considerations: the first fatigue tests were performed on materials that had been observed to fail after repeated loading of a magnitude less than that required for failure under the application of a single load. Mine-hoist chains (1829), railway axles (1852), and steam engine parts were among the first structural components to be recognized as exhibiting fatigue behavior. Since concrete is usually subjected to static loading rather than cyclic loading, need for knowledge of the fatigue behavior of concrete has lagged behind that of metals. One notable exception to this, however, is in the area of highway and airfield pavement design. Due to the fact that the fatigue behavior of concrete must be understood in the design of pavements and reinforced concrete bridges, highway engineers have provided the motivation for concrete fatigue studies since the 1920s.

Evaluation of Fly Ash in Portland Cement Concrete Paving in Woodbury County, Iowa, Final Report, HR-201, 1980

The earliest overall comprehensive work on the use of fly ash in concrete was reported by Davis and Associates of the University of California in 1937. Since that time, there have been numerous applications of the use and varying propertions of fly ash in portland cement concrete mixes. Fly ash is a pozzolanic powdery by-product of the coal combustion process which is recovered from flue gases and is, generally associated with electric power generating plants. Environmental regulations enacted in recent years have required that fly ash be removed from the flue gases to maintain clean air standards. This has resulted in an increased volume of high quality fly ash that is considered a waste product or a by-product that can be utilized in products such as portland cement concrete. There are several sources of the high quality fly ash located in Iowa currently producing a combined total of 281,000 tons of material annually.

Performance of Concrete Bridge Deck Overlays, HR-501, 1990

Chloride-ions penetrating into bridge decks and corroding the steel have been a major problem. As the steel corrodes it exerts stresses on the surrounding concrete. When the stresses exceed the strength of the concrete, cracks or delaminations occur. This, of course, causes deterioration and spalling of bridge deck surfaces. Both the Latex and Iowa Method were used to repair bridge decks for this project. The concrete was removed down to the steel and replaced with approximately 1 1/2 inches of low slump or latex modified concrete. The removal of unsound concrete below the top layer of steel was sometimes necessary. The objective of this project was to determine if the bridge overlays would provide a cost effective method of rehabilitation. To do this, unsound and delaminated concrete was removed and replaced by an overlay of low slump or latex modified concrete.

Thin Bonded Concrete Overlay with Fast Track Concrete, Final Report, HR-531, 1990

Pavements have been overlaid with thin bonded portland cement concrete (PCC) for several years. These projects have had traffic detoured for a period of 5-10 days. These detours are unacceptable to the traveling public and result in severe criticism. The use of thin bonded fast track overlay was promoted to allow a thin bonded PCC overlay with minimal disruption of local traffic. This project demonstrated the concept of using one lane of the roadway to maintain traffic while the overlay was placed on the other and then with the rapid strength gain of the fast track concrete, the construction and local traffic is maintained on the newly placed, thin bonded overlay. The goals of this project were: 1. Traffic usage immediately after placement and finishing. 2. Reduce traffic disruption on a single lane to less than 5 hours. 3. Reduce traffic disruption on a given section of two-lane roadway to less than 2 days. 4. The procedure must be economically viable and competitive with existing alternatives. 5. Design life for new construction equivalent to or in excess of conventional pavements. 6. A 20 year minimum design life for rehabilitated pavements.

Evaluation of Paver Vibrator Frequency Monitoring and Concrete Consolidation, HR-1068, 1999

Identification of ways to enhance consistency and proper entrained air content in hardened concrete pavement has long been a goal of state highway agencies and the Federal Highway Administration. The work performed in this study was done under FHWA Work Order No: DTFH71-97-PTP-IA-47 and referred to as Project HR-1068 by the Iowa DOT. The results of this study indicate that the monitoring devices do provide both the contractor and contracting authority and are a good way of controlling the consistent rate of vibration to achieve a quality concrete pavement product. The devices allow the contractor to monitor vibrator operation effectively and consistently. The equipment proved to be reliable under all weather and paver operating conditions. This type of equipment adds one more way of improving the consistency and quality of the concrete pavement.

Evaluation of Fly Ash in Bridge Deck Concrete, MLR-84-2, 1985

Fly ash was used in this evaluation study to replace 15% of the cement in Class D-57 structural concrete containing ASTM C494 Type B, retarding admixtures. Two Class "C" ashes and one Class "F" ash from Iowa approved sources were examined in each mix. When Class "C" ashes were used, they were substituted on the basis of 1.0 pound for each pound of cement removed. When Class "F" ash was used, it was substituted on the basis of 1.25 pounds of ash for each pound of cement removed. Compressive strengths of the retarded mixes, with and without fly ash, were determined at 7, 28 and 56 days of age. In most cases, with few exceptions, the mixes containing the fly ash exhibited higher strengths than the same concrete mix without the fly ash. The exceptions were the 7, 28, and 56 days of the mixes containing Class F ash. The freeze/thaw durability of the concrete studied was not affected by the presence of fly ash. The data obtained suggested that the present Class D-57 structural concrete mix with retarding admixtures can be modified to allow the substitution of 15% of the cement with an approved fly ash when Class III coarse aggregates are used. Setting times of the concretes were not materially changed due to the incorporation of fly ash.

Evaluation of Rapid Determination of the Chloride Permeability of Portland Cement Concrete by AASHTO T277-83, MLR-86-11, 1987

An Iowa D.O.T. Laboratory built machine was constructed for the chloride permeability testing of concrete by measuring electric current through a specimen between a salt solution and a base solution. This study had two purposes. The first was to evaluate the machine's performance. To do this, three concrete mixes were made consisting of different cement factors and water/cement ratios. Each mix was tested for chloride ion content by the 90- day salt ponding method and for chloride permeability at a 28-day cure by the permeability machine. The results from each test were evaluated to see if there was correlation between chloride ion content and the chloride permeability. It was determined that there was a correlation and that the permeability machine was satisfactory for determining chloride permeability in concrete. The second purpose of this study was to examine the effects that pozzolans have on the chloride permeability of concrete. Four mixes were made: one without any pozzolans as a control, one with class C fly ash, one with class F fly ash, and one with silica fume. Specimens from each mix were evaluated for chloride ion content by the 90-day salt ponding test and by the laboratory built machine for chloride permeability after curing 28 days. Specimens from these mixes were also taken from the salt ponding slabs after completion of the ponding test to examine the effect chloride ion content has on the operation of the chloride permeability machine. Specimens containing pozzolans were also examined for chloride permeability after a cure of 180 days. It was determined that the addition of pozzolans to concrete lowers the chloride permeability as measured by the permeability machine. Class F fly ash and silica fume in the concrete had a major effect in lowering the chloride permeability in concrete as measured by the permeability machine.

Frictional Properties of Asphalt Concrete Pavements in Iowa, MLR-87-5, 1987

Friction testing of pavements has been a continuing effort by the Iowa Department of Transportation since 1969. This report details results of tests of asphaltic concrete pavements on the primary and interstate road systems. Both sprinkle treated and non-sprinkle treated pavements placed between 1975 - 1985 are included. A total of 1785 miles representing 216 separate paving projects were examined. The effect of fog sealing sprinkle treated pavements was studied by testing friction levels before and after the application of the fog seals. Conclusions of the report are: 1. Current aggregate selection criteria for a.c. pavement surface courses provides adequate friction levels through 10 years and should remain effective through a 15 year design life. 2. Sprinkle treatment of pavements has, for the most part, provided macrotexture in the pavement surface as evidenced by smooth tire testing. 3. Fog sealing sprinkle treated pavements does not significantly alter the friction properties.

Fine Sand for Use in PC Concrete, MLR-88-6, 1989

In several locations of Iowa, it is becoming more difficult to produce concrete sand consistently at a reasonable cost. Both ASTM and AASHTO have specifications for concrete sands that allow a finer, poorer graded sand than Iowa specifications. The objective of the study was to develop standard mix designs to permit the use of finer graded sand for PC concrete. Three hundred cylinders were made from five sands available in the state. Based on the results of the study, the following are recommended: (1) Create another class of concrete sand by: (a) lowering the current mortar strength ratio from 1.5 to 1.3, (b) raising the allowance for the percent passing one sieve and retained on the next from 40 to 45, and (c) including a provision that 25 to 60 percent passing the number 30 sieve is required for the sand; and (2) Modify the standard paving mixes with and without fly ash for use with the finer sand as follows: (a) 8% more cement and fly ash for B-2 to B-5 mixes, (b) 7% more cement and fly ash for A-2 to A-5 mixes, and (c) 5% more cement and fly ash for C-2 to C-5 mixes and water reduced mixes.

Thin Bonded Concrete Resurfacing U.S. 34 West Burlington, Iowa, HR-34

The Experimental Project was designated as Research Project No. HR-34, sponsored by the Iowa Highway Research Board and constructed by the Iowa Highway Commission. Construction was supervised cooperatively by Engineers of the Iowa Highway Commission and the Portland Cement Association. The objective of the experiment is to study the behavior of relatively thin portland cement concrete resurfacing courses placed with bond on old concrete pavements. The phase of the problem being studied now, involves only pavements in which the old concrete is structurally sound.

A Further Evaluation of Concrete Bridge Deck Surfacing in Iowa, MLR-79-1, 1979

The Iowa Department of Transportation has overlaid 446 bridge decks with low slump dense concrete from 1964 through October 1978. The overall performance of these decks has been satisfactory. Nineteen bridges that were resurfaced with either low slump dense concrete (LSDC) or latex-modified concrete were analyzed for chloride content, electrical corrosion potential, delaminations or debonding, and deck surface condition. The resurfacing ages of these bridges range from 5 to 13 years. None of the bridges showed any evidence of surface distress and the chloride penetration into the resurfacing concrete is relatively low. There are delaminations in the original decks below the resurfacing on the majority of bridges examined. The delaminations are concluded to be caused by either (A) reinforcing steel corrosion, (B) not removing all delaminated concrete prior to placing the resurfacing concrete, or (C) creating an incipient fracture in the top surf ace of the original deck through the use of scarification equipment. The active corrosion of the reinforcing steel is predominately in the gutter line on the majority of bridges evaluated. Recommendations for future deck repairs include removal of concrete to the top layer of reinforcing steel in areas where an electrical corrosion potential of -0.35V or more is detected, providing more positive methods of locating delaminated concrete, and treating the curb and gutter line to reduce the potential damage from salt water.