Low Cost Fly Ash - Sand Stabilization Roadway, Construction Report, HR-259, 1986

Fly ash, a by-product of coal-fired electricity generating plants, has for years been promoted as a material suitable for highway construction. Disposal of the large quantities of fly ash produced is expensive and creates environmental concerns. The pozzolanic properties make it promotable as a partial Portland cement replacement in pc concrete, a stabilizer for soil and aggregate in embankments and road bases, and a filler material in grout. Stabilizing soils and aggregates for road construction has the potential of using large quantities of fly ash. Iowa Highway Research Board Project HR-194, "Mission-Oriented Dust Control and Surface Improvement Processes for Unpaved Roads", included short test sections of cement, fly ash, and salvaged granular road material mixed for a base in western Iowa. The research showed that cement fly ash aggregate (CFA) has promise as a stabilizing agent in Iowa. There are several sources of sand that when mixed with fly ash may attain strengths much greater than fly ash mixed with salvaged granular road material at little additional cost

Evaluating the Relationship between the Driver and Roadway to Address Rural Intersection Safety using the SHRP 2 Naturalistic Driving Study Data, RB05-013, 2016

Rural intersections account for 30% of crashes in rural areas and 6% of all fatal crashes, representing a significant but poorly understood safety problem. Transportation agencies have traditionally implemented countermeasures to address rural intersection crashes but frequently do not understand the dynamic interaction between the driver and roadway and the driver factors leading to these types of crashes. The Second Strategic Highway Research Program (SHRP 2) conducted a large-scale naturalistic driving study (NDS) using instrumented vehicles. The study has provided a significant amount of on-road driving data for a range of drivers. The present study utilizes the SHRP 2 NDS data as well as SHRP 2 Roadway Information Database (RID) data to observe driver behavior at rural intersections first hand using video, vehicle kinematics, and roadway data to determine how roadway, driver, environmental, and vehicle factors interact to affect driver safety at rural intersections. A model of driver braking behavior was developed using a dataset of vehicle activity traces for several rural stop-controlled intersections. The model was developed using the point at which a driver reacts to the upcoming intersection by initiating braking as its dependent variable, with the driver’s age, type and direction of turning movement, and countermeasure presence as independent variables. Countermeasures such as on-pavement signing and overhead flashing beacons were found to increase the braking point distance, a finding that provides insight into the countermeasures’ effect on safety at rural intersections. The results of this model can lead to better roadway design, more informed selection of traffic control and countermeasures, and targeted information that can inform policy decisions. Additionally, a model of gap acceptance was attempted but was ultimately not developed due to the small size of the dataset. However, a protocol for data reduction for a gap acceptance model was determined. This protocol can be utilized in future studies to develop a gap acceptance model that would provide additional insight into the roadway, vehicle, environmental, and driver factors that play a role in whether a driver accepts or rejects a gap.

Development and Evaluation of a Portable Device for Measuring Curling and Warping in Concrete Pavements, 2016

Portland cement concrete (PCC) pavement undergoes repeated environmental load-related deflection resulting from temperature and moisture variations across pavement depth. This has been recognized as resulting in PCC pavement curling and warping since the mid-1920s. Slab curvature can be further magnified under repeated traffic loads and may ultimately lead to fatigue failures, including top-down and bottom-up transverse, longitudinal, and corner cracking. It is therefore significant to measure the “true” degree of curling and warping in PCC pavements, not only for quality control (QC) and quality assurance (QA) purposes, but also for better understanding of its relationship to long-term pavement performance. Although several approaches and devices—including linear variable differential transducers (LVDTs), digital indicators, and some profilers—have been proposed for measuring curling and warping, their application in the field is subject to cost, inconvenience, and complexity of operation. This research therefore explores developing an economical and simple device for measuring curling and warping in concrete pavements with accuracy comparable to or better than existing methodologies. Technical requirements were identified to establish assessment criteria for development, and field tests were conducted to modify the device to further enhancement. The finalized device is about 12 inches in height and 18 pounds in weight, and its manufacturing cost is just $320. Detailed development procedures and evaluation results for the new curling and warping measuring device are presented and discussed, with a focus on achieving reliable curling and warping measurements in a cost effective manner.

Embankment Quality and Assessment of Moisture Control Implementation, TR-677, 2016

A specification for contractor moisture quality control (QC) in roadway embankment construction has been in use for approximately 10 years in Iowa on about 190 projects. The use of this QC specification and the development of the soils certification program for the Iowa Department of Transportation (DOT) originated from Iowa Highway Research Board (IHRB) embankment quality research projects. Since this research, the Iowa DOT has applied compaction with moisture control on most embankment work under pavements. This study set out to independently evaluate the actual quality of compaction using the current specifications. Results show that Proctor tests conducted by Iowa State University (ISU) using representative material obtained from each test section where field testing was conducted had optimum moisture contents and maximum dry densities that are different from what was selected by the Iowa DOT for QC/quality assurance (QA) testing. Comparisons between the measured and selected values showed a standard error of 2.9 lb/ft3 for maximum dry density and 2.1% for optimum moisture content. The difference in optimum moisture content was as high as 4% and the difference in maximum dry density was as high as 6.5 lb/ft3 . The difference at most test locations, however, were within the allowable variation suggested in AASHTO T 99 for test results between different laboratories. The ISU testing results showed higher rates of data outside of the target limits specified based on the available contractor QC data for cohesive materials. Also, during construction observations, wet fill materials were often observed. Several test points indicated that materials were placed and accepted at wet of the target moisture contents. The statistical analysis results indicate that the results obtained from this study showed improvements over results from previous embankment quality research projects (TR-401 Phases I through III and TR-492) in terms of the percentage of data that fell within the specification limits. Although there was evidence of improvement, QC/QA results are not consistently meeting the target limits/values. Recommendations are provided in this report for Iowa DOT consideration with three proposed options for improvements to the current specifications. Option 1 provides enhancements to current specifications in terms of material-dependent control limits, training, sampling, and process control. Option 2 addresses development of alternative specifications that incorporate dynamic cone penetrometer or light weight deflectometer testing into QC/QA. Option 3 addresses incorporating calibrated intelligent compaction measurements into QC/QA.

Nondestructive Evaluation and Assessment of Concrete Barriers for Defects and Corrosion, 2013

Wiss, Janney, Elstner Associates, Inc. (WJE) evaluated potential nondestructive evaluation (NDE) methodologies that may be effective in 1) identifying internal defects within slip formed concrete barriers and 2) assessing the corrosion condition of barrier dowel bars. The evaluation was requested by the Bridge Maintenance and Inspection Unit of the Iowa Department of Transportation (IaDOT) and the Bureau of Bridges and Structures of the Illinois Department of Transportation (IDOT). The need arose due to instances in each Department’s existing inventory of bridge barriers where internal voids and other defects associated with slip forming construction methods were attributed to poor barrier performance after completion of construction and where, in other barrier walls, unintentional exposure of the dowel bars revealed extensive corrosion-related section loss at previously uninspectable locations, reducing the capacity of the barriers to resist traffic impact loads. WJE trial tested potential NDE techniques on laboratory mock-up samples built with known defects, trial sections of cast-in-place barriers at in-service bridges in Iowa, and slip formed and cast-in-place barrier walls at in-service bridges in Illinois. The work included review of available studies performed by others, field trial testing to assess candidate test methods, verification of the test methods in identifying internal anomalies and dowel bar corrosion, and preparation of this report and nondestructive evaluation guidelines.

Air Formed Arch Culvert Construction: Crawford County, Construction Reports, HR-314, 1991

Iowa's secondary roads contain nearly 15,000 bridges which are less than 40 feet (12 m) in length. Many of these bridges were built several decades ago and need to be replaced. Box culvert construction has proven to be an adequate bridge replacement technique. Recently a new bridge replacement alternative, called the Air-0-Form method, has emerged which has several potential advantages over box culvert construction. This new technique uses inflated balloons as the interior form in the construction of an arch culvert. The objective of research project HR-314 was to construct an air formed arch culvert to determine the applicability of the Air-O-Form technique as a county bridge replacement alternative.

High Molecular Weight Methacrylate Sealing of a Bridge Deck, HR-2031, Construction Report, 1988

The Iowa Department of Transportation used a high molecular weight methacrylate (HMWM) resin to seal a 3,340 ft. x 64 ft. bridge deck in October 1986. The sealing was necessary to prevent deicing salt brine from entering a substantial number of transverse cracks that coincided with the epoxy coated top steel and unprotected bottom steel. HMWM resin is a three component product composed of a monomer, a curnene hydroperoxide initiator and a cobalt naphthenate promoter. The HMWM was applied with a dual spray bar system and flat-fan nozzles. Initiated monomer delivered through one spray bar was mixed in the air with promoted monomer from the other spray bar. The application rate averaged 0.956 gallons per 100 square feet for the tined textured driving lanes. Dry sand was broadcast on the surface at an average coverage of 0.58 lbs. per square yard to maintain friction. Coring showed that the H.MWM resin penetrated the cracks more than two inches deep. Testing of the treated deck yielded Friction Numbers averaging 33 with a treaded tire compared to 36 prior to treatment. An inspection soon after treatment found five leaky cracks in one of the 15 spans. One inspection during a steady rain showed no leakage, but leakage from numerous cracks occurred during a subsequent rain. A second HMWM application was made on two spans to determine if a double application would prevent leakage. This evaluation has not been completed.

Evaluation of Unbonded Ultrathin Whitetopping of Brick Streets, TR-466, Construction Report, 2002

Many cities in Iowa have retained the original brick street surfaces in downtown areas and in older residential areas as the base for modern driving surfaces. The original brick surfaces were not built to handle current and future traffic loadings. In recent years, these surfaces have tended to shift and become uneven, creating problems with safety. Asphaltic concrete overlays have been the typical rehabilitation technique in these situations. This has proven to be a successful rehabilitation technique in some cases; in other cases, the combination of movement of the brick and flexibility of the asphalt has proven to accentuate the original problems. Most of the existing literature on rehabilitation of brick streets shows the use of asphaltic concrete. Other rehabilitation methods include reconstruction of the brick surface and strengthening of the surface by placing asphaltic concrete or portland cement concrete, along with sand, underneath the brick layers. To date, little if anything has been done in the area of using portland cement concrete as an overlay of the brick surfaces. This final report documents the planning, construction, and performance of unbonded ultrathin whitetopping rehabilitation of a brick street in Oskaloosa, Iowa, in 2001. It also reports on a similar project in Des Moines that was constructed two years later in 2003.

Investigation of Techniques for Accelerating the Construction of Bridge Deck Overlays, 2016

Use of bridge deck overlays is important in maximizing bridge service life. Overlays can replace the deteriorated part of the deck, thus extending the bridge life. Even though overlay construction avoids the construction of a whole new bridge deck, construction still takes significant time in re-opening the bridge to traffic. Current processes and practices are time-consuming and multiple opportunities may exist to reduce overall construction time by modifying construction requirements and/or materials utilized. Reducing the construction time could have an effect on reducing the socioeconomic costs associated with bridge deck rehabilitation and the inconvenience caused to travelers. This work included three major tasks with literature review, field investigation, and laboratory testing. Overlay concrete mix used for present construction takes long curing hours and therefore an investigation was carried out to find fast-curing concrete mixes that could reduce construction time. Several fast-cuing concrete mixes were found and suggested for further evaluation. An on-going overlay construction project was observed and documented. Through these observations, several opportunities were suggested where small modifications in the process could lead to significant time savings. With current standards of the removal depth of substrate concrete in Iowa, it takes long hours for the removal process. Four different laboratory tests were performed with different loading conditions to determine the necessary substrate concrete removal depth for a proper bond between the substrate concrete and the new overlay concrete. Several parameters, such as failure load, bond stress, and stiffness, were compared for four different concrete removal depths. Through the results and observations of this investigation several conclusions were made which could reduce bridge deck overlay construction time.

Evaluation of Recycled Rubber in Asphalt Concrete, HR-330, Construction Report, 1991

Discarded tires present major disposal and environmental problems. The recycling of those tires in asphalt cement concrete is what this research deals with. The Iowa DOT and the University of Northern Iowa (UNI) are evaluating the use of discarded tires in asphalt rubber cement and rubber chip mixes. The project is located on US 61 between Blue Grass and Muscatine in Muscatine County. It contains four rubberized asphalt sections and control sections. One section consists of reacted rubber asphalt cement used in both the binder and surface courses, and one section, both lanes, contains a rubber chip mix. The reacted rubber asphalt and the rubber chip mixes were laid in July 1991. The project construction went well with a few problems of shoving and cracking of the mat. This report contains information about procedures and tests that were run and those that will be run. It also has a cost comparison since this is a major concern with the use of asphalt rubber. Evaluation of this project will continue for five years. Three more research projects containing rubberized asphalt were constructed in 1991 and another is to be constructed in 1992.

Addendum to the Design Manual for Low Water Stream Crossings, HR-247, 1984

The purpose of this manual is to provide guidelines for low water stream crossings (LWSC). Rigid criteria for determining the applicability of a LWSC to a given site are not established nor is a 'cookbook" procedure for designing a LWSC presented. Because conditions vary from county to county and from site to site within the county, judgment must be applied to the suggestions contained in this manual. A LWSC is a stream crossing that will be flooded periodically and closed to traffic. Carstens (1981) has defined a LWSC as "a ford, vented ford (one having some number of culvert pipes), low water bridge, or other structure that is designed so that its hydraulic capacity will be insufficient one or more times during a year of normal rainfall." In this manual, LWSC are subdivided into these same three main types: unvented fords, vented fords and low water bridges. Within the channel banks, an unvented ford can have its road profile coincident with the stream bed or can have its profile raised some height above the stream bed.

Low Cost Techniques of Base Stabilization, HR-312, Construction Report, 1989

This research project was initiated in 1988 to study the effectiveness of four different construction techniques for establishing a stable base on a granular surfaced roadway. After base stabilization, the roadway was then seal coated, eliminating dust problems associated with granular surfaced roads. When monies become available, the roadway can be surfaced with a more permanent structure. A 2.8 mile section of the Horseshoe Road in Dubuque County was divided into four divisions for the study. This report discusses the procedures used during construction of these different divisions. Problems and possible solutions have been analyzed to better understand the capabilities of the materials and construction techniques used on the project.

Evaluation of Recycled Rubber in Asphalt Concrete - Black Hawk County, HR-330B, Construction Report, 1992

The disposal of discarded tires has become a major problem. Different methods of recycling have been researched. Currently, Iowa is researching the use of ground recycled crumb rubber from discarded tires in asphalt rubber cement. Six projects have been completed in Iowa using asphalt rubber cement. This project is located on IA 947 (University Avenue) in Cedar Falls/Waterloo. The project contains one section with asphalt rubber cement used in both the binder and surface courses and one section using asphalt rubber cement in the surface course with a conventional binder. There are two control sections where conventional asphalt pavement was placed.

The Use of Fly Ash in Highway Construction, HR-1031, Progress Report, 1986

In 1982 the Iowa DOT allowed a successful bidder the option of submitting materials and proportions using fly ash to produce a portland cement concrete (PCC) paving mixture to meet a specified compressive strength. The contractor, Irving F. Jensen, received approval for the use of a concrete mixture utilizing 500 lbs. of portland cement and 88 lbs. of fly ash as a replacement of 88 lbs. of portland cement. The PCC mixture was utilized on the Muscatine County US 61 relocation bypass paved as project F-61-4(32)--20-70. A Class "C" fly ash obtained from the Chillicothe electric generating plant approximately 100 miles away was used in the project. This use of fly ash in lieu of portland cement resulted in a cost savings of $64,500 and an energy savings of approximately 16 billion BTU. The compressive strength of this PCC mixture option was very comparable to concrete mixtures produced without the use of fly ash. The pavement has been performing very well. The substitution of fly ash for 15% of the cement has been allowed as a contractor's option since 1984. Due to the cost savings, it has been used in almost all Iowa PCC paving since that time.

Ammonium Phosphate/Fly Ash Road Base Construction, HR-294, Construction Report, 1987

The objective of this research project was to evaluate the construction and service performance of ammonium phosphate/fly ash (APFA) treated base courses of crushed fines and/or unprocessed sand. Specific test results related to construction of the test sections were included in the 1987 construction report by Iowa State University. The performance of the experimental sections is dealt with in this final report. This 1986 project demonstrated that in all cases the control sections utilizing a Type B base experienced dramatically less cracking in the surface than the APFA treated base sections. The cost per mix and subsequent surface maintenance costs for the APFA base sections, especially those having a substantial amount of limestone, were higher than the Type B base control sections. This type of construction may prove to be economical only when petroleum product costs escalate.