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.

Production of Acetic Acid by Fermentation with Propionibacteria, HR-321, 1993

This project was undertaken jointly with a project supported by the Iowa Corn Promotion Board. Together the projects aimed at producing the organic acids, propionic acid and acetic acid, by fermentation. The impacts were to provide agriculturally-based alternatives to production of these acids, currently produced mainly as petrochemicals. The potentially high-demand use for acetic acid is as the "acetate" in Calcium Magnesium Acetate (CMA), the non-corrosive road deicer. Fermentation was, however, far from being an economically acceptable alternative. Gains were made in this work toward making this a feasible route. These advances included (1) development of a variant strain of propionibacteria capable of producing higher concentrations of acids; (2) comparison of conditions for several ways of cultivating free cells and establishment of the relative benefits of each; (3) achievement of the highest productivity in fermentations using immobilized cells; (4) identification of corn steep liquor as a lower cost substrate for the fermentation; (5) application of a membrane extraction system for acid recovery and reduction of product inhibition; and (6) initial use of more detailed economic analysis of process alternatives to guide in the identification of where the greatest payback potential is for future research. At this point, the fermentation route to these acids using the propionibacteria is technically feasible, but economically unfeasible. Future work with integration of the above process improvements can be expected to lead to further gains in economics. However, such work can not be expected to make CMA a less expensive deicer than common road salt.

Iowa Department of Transportation Major Items - Preliminary Quantity Report, January 22, 2014; With Addendums

Weekly letting report.

The Potential of Friction as a Tool for Winter Maintenance, TR-400, 1998

It is intuitively obvious that snow or ice on a road surface will make that surface more slippery and thus more hazardous. However, quantifying this slipperiness by measuring the friction between the road surface and a vehicle is rather difficult. If such friction readings could be easily made, they might provide a means to control winter maintenance activities more efficiently than at present. This study is a preliminary examination of the possibility of using friction as an operational tool in winter maintenance. In particular, the relationship of friction to traffic volume and speed, and accident rates is examined, and the current lack of knowledge in this area is outlined. The state of the art of friction measuring techniques is reviewed. A series of experiments whereby greater knowledge of how friction deteriorates during a storm and is restored by treatment is proposed. The relationship between plowing forces and the ice-pavement bond strength is discussed. The challenge of integrating all these potential sources of information into a useful final product is presented together with a potential approach. A preliminary cost-benefit analysis of friction measuring devices is performed and suggests that considerable savings might be realized if certain assumptions should hold true. The steps required to bring friction from its current state as a research tool to full deployment as an operational tool are presented and discussed. While much remains to be done in this regard, it is apparent that friction could be an extremely effective operational tool in winter maintenance activities of the future.

The Role of Magnesium in Concrete Deterioration, HR-355, 1994

Concretes with service lives of less than 15 years and those with lives greater than 40 years were studied with petrographic microscope, scanning electron microscope, and electron microprobe to determine why these two groups of concrete exhibit such different degrees of durability under highway conditions. Coarse aggregate used in both types of concrete were from dolomite rock, but investigation revealed that dolomite aggregate in the two groups of concretes were much different in several respects. The poorly-performing aggregate is fine-grained, has numerous euhedral and subhedral dolomite rhombohedra, and has relatively high porosity. Aggregate from durable concrete is coarse-grained, with tightly interlocked crystal fabric, anhedral dolomite boundaries, and low porosity. Aggregate in short service life concrete was found to have undergone pervasive chemical reactions with the cement which produced reaction rims on the boundaries of coarse aggregate particles and in the cement region adjacent to aggregate boundaries. Textural and porosity differences are believed to be chiefly responsible for different service lives of the two groups of concrete. The basic reaction that has occurred in the short service life concretes between coarse aggregate and cement is an alkali-dolomite reaction. In the reaction dolomite from the aggregate reacts with hydroxide ions from the cement to free magnesium ions and carbonate ions, and the magnesium ions precipitate as brucite, Mg(OH)2. Simultaneously with this reaction, a second reaction occurs in which product carbonate ions react with portlandite from the cement to form calcite and hydroxide ions. Crystal growth pressures of newly formed brucite and calcite together with other processes, e.g. hydration state changes of magnesium chloride hydrates, lead to expansion of the concretes with resultant rapid deterioration. According to this model, magnesium from any source, either from reacting dolomite or from magnesium road deicers, has a major role in highway concrete deterioration. Consequently, magnesium deicers should be used with caution, and long-term testing of the effects of magnesium deicers on highway concrete should be implemented to determine their effects on durability.

Investigation of Two Bridge Alternatives for Low Volume Roads, Volume 1 of 2 Concept 1: Precast Steel Beam Units, HR-382, 1997

Recent reports have indicated that 23.5% of the nation's highway bridges are structurally deficient and 17.7% are functionally obsolete. A significant number of these bridges are on the Iowa secondary road system where over 86% of the rural bridge management responsibilities are assigned to the counties. Some of the bridges can be strengthened or otherwise rehabilitated, but many more are in need of immediate replacement. In a recent investigation (HR-365 "Evaluation of Bridge Replacement Alternatives for the County Bridge System") several types of replacement bridges that are currently being used on low volume roads were identified. It was also determined that a large number of counties (69%) have the ability and are interested in utilizing their own forces to design and construct short span bridges. In reviewing the results from HR-365, the research team developed one "new" bridge replacement concept and a modification of a replacement system currently being used. Both of these bridge replacement alternatives were investigated in this study, the results of which are presented in two volumes. This volume (Volume 1) presents the results of Concept 1 - Steel Beam Precast Units. Concept 2 - Modification of the Beam-in-Slab Bridge is presented in Volume 2. Concept 1, involves the fabrication of precast units (two steel beams connected by a concrete slab) by county work forces. Deck thickness is limited so that the units can be fabricated at one site and then transported to the bridge site where they are connected and the remaining portion of the deck placed. Since Concept 1 bridge is primarily intended for use on low-volume roads, the precast units can be constructed with new or used beams. In the experimental part of the investigation, there were three types of static load tests: small scale connector tests, "handling strength" tests, and service and overload tests of a model bridge. Three finite element models for analyzing the bridge in various states of construction were also developed. Small scale connector tests were completed to determine the best method of connecting the precast double-T (PCDT) units. "Handling strength" tests on an individual PCDT unit were performed to determine the strength and behavior of the precast unit in this configuration. The majority of the testing was completed on the model bridge [L=9,750 mm (32 ft), W=6,400 mm (21 ft)] which was fabricated using the precast units developed. Some of the variables investigated in the model bridge tests were number of connectors required to connect adjacent precast units, contribution of diaphragms to load distribution, influence of position of diaphragms on bridge strength and load distribution, and effect of cast-in-place portion of deck on load distribution. In addition to the service load tests, the bridge was also subjected to overload conditions. Using the finite element models developed, one can predict the behavior and strength of bridges similar to the laboratory model as well as design them. Concept 1 has successfully passed all laboratory testing; the next step is to field test it.

Investigation of Two Bridge Alternatives for Low Volume Roads - Phase II Volume 1 of 2 Concept 1: Steel Beam Precast Units, TR-410, 2000

This project continues the research which addresses the numerous bridge problems on the Iowa secondary road system. It is a continuation (Phase 2) of Project HR-382, in which two replacement alternatives (Concept 1: Steel Beam Precast Units and Concept 2: Modification of the Benton County Beam-in-Slab Bridge) were investigated. In previous research for concept 1, a precast unit bridge was developed through laboratory testing. The steel-beam precast unit bridge requires the fabrication of precast double-tee (PCDT) units, each consisting of two steel beams connected by a reinforced concrete deck. The weight of each PCDT unit is minimized by limiting the deck thickness to 4 in., which permits the units to be constructed off-site and then transported to the bridge site. The number of units required is a function of the width of bridge desired. Once the PCDT units are connected, a cast-in-place reinforced concrete deck is cast over the PCDT units and the bridge railing attached. Since the steel beam PCDT unit bridge design is intended primarily for use on low-volume roads, used steel beams can be utilized for a significant cost savings. In previous research for concept 2, an alternate shear connector (ASC) was developed and subjected to static loading. In this investigation, the ASC was subjected to cyclic loading in both pushout specimens and composite beam tests. Based on these tests, the fatigue strength of the ASC was determined to be significantly greater than that required in typical low volume road single span bridges. Based upon the construction and service load testing, the steel-beam precast unit bridge was successfully shown to be a viable low volume road bridge alternative. The construction process utilized standard methods resulting in a simple system that can be completed with a limited staff. Results from the service load tests indicated adequate strength for all legal loads. An inspection of the bridge one year after its construction revealed no change in the bridge's performance. Each of the systems previously described are relatively easy to construct. Use of the ASC rather than the welded studs significantly simplified the work, equipment, and materials required to develop composite action between the steel beams and the concrete deck.

Field Evaluation of Class A Subbase Using Fly Ash, MLR-87-3, 1988

This project consisted of slipforming a 4-inch thick econocrete subbase on a 6-mile section of US 63. The project location extends south from one mile south of Denver, Iowa to Black Hawk County Road C-66 and consisted of the reconstruction and new construction of a divided four-lane facility. The econocrete was placed 27.3 feet wide in a single pass. Fly ash was used in this field study to replace 30, 45 and 60 percent of the portland cement in three portland cement econocrete base paving mixes. The three mixes contained 300, 350 and 400 pounds of cementitious material per cubic yard. Two Class "C" ashes from Iowa approved sources were used. The ash was substituted on the basis of one pound of ash for each pound of cement removed. The work was done October 6-29, 1987 and May 25-June 9, 1988. The twelve subbase mixes were placed in sections 2500 to 3000 feet in length on both the north and southbound roadways. Compressive strengths of all mixes were determined at 3 and 28 days of age. Flexural strengths of all mixes were determined at 7 and 14 days. In all cases strengths were adequate. The freeze/thaw durability of the econocrete mixes used was reduced by increased fly ash levels but remained above acceptable limits. The test results demonstrate the feasibility of producing econocrete with satisfactory properties even using fly ash at substitution rates up to 45 percent.

Lightweight Aggregate Use in Structural Concrete, MLR-69-1 and R-229, 1969

The Iowa State Highway Commission has adopted a number of rigid safety requirements that the Bureau of Public Roads has set forth as standards for road construction. One of these safety requirements is the elimination of two piers on Interstate grade separations, thus leaving two long spans. These longer spans lower the ability of prestressed concrete beams to compete economically with steel beams. In an effort to be more competitive, the prestressing companies have been studying the use of lightweight aggregate in structural concrete.

A Sufficiency Rating System for Secondary Roads in Iowa, HR-264, Volume I, 1985

County engineers in Iowa face the dual problems of rapidly escalating costs and a decreasing rate of growth of revenues. Various priority systems are in use, ranking projects for inclusion in road improvement programs, but they generally have weaknesses when used to compare one project with another in a different location. The sufficiency rating system has proven to be a useful tool in developing a priority list of projects for primary road systems, but there are none currently in use for secondary road systems. The research reported here was undertaken to develop a sufficiency rating system which could be used for secondary roads in Iowa and to produce the necessary forms and instructions to aid county engineering personnel in their efforts to complete the ratings for roads within their county.

Iowa Department of Transportation Major Items - Preliminary Quantity Report, March 18, 2014; With Addendums

Weekly letting report.

Iowa Development of Roller Compacted Concrete, HR-300, 1989

Roller compacted concrete (RCC) is a zero slump portland cement concrete mixture that has been used since the early 1970's in massive concrete structures. Iowa Highway Research Board project HR-300 was established to determine if this type mix could be used to pave roads on the Iowa road system. Manatt's Inc. of Brooklyn, Iowa agreed to pave an 800 ft. x 22 ft. x 10 in. section of RCC pavement in their Ames construction yard. This report discusses the construction of the test slab and interprets test results conducted during and after construction. It was observed that RCC can be placed with conventional asphalt paving equipment. However, there are several problems with RCC paving which must be resolved before RCC can become a viable paving alternative on Iowa's roadway system.

Strengthening of an Existing Continuous-Span, Steel-Beam, Concrete-Deck Bridge by Post-Tensioning, HR-308, 1990

The need to upgrade a large number of understrength and obsolete bridges in the U.S. has been well documented in the literature. Through several Iowa DOT projects, the concept of strengthening simple-span bridges by post-tensioning has been developed. The purpose of the project described in this report was to investigate the use of post-tensioning for strengthening continuous composite bridges. In a previous, successfully completed investigation, the feasibility of strengthening continuous, composite bridges by post-tensioning was demonstrated on a laboratory 1/3-scale-model bridge (3 spans: 41 ft 11 in. x 8 ft 8 in.). This project can thus be considered the implementation phase. The bridge selected for strengthening was in Pocahontas County near Fonda, Iowa, on County Road N28. With finite element analysis, a post-tensioning system was developed that required post-tensioning of the positive moment regions of both the interior and exterior beams. During the summer of 1988, the strengthening system was installed along with instrumentation to determine the bridge's response and behavior. Before and after post-tensioning, the bridge was subjected to truck loading (1 or 2 trucks at various predetermined critical locations) to determine the effectiveness of the strengthening system. The bridge, with the strengthening system in place, was inspected approximately every three months to determine any changes in its appearance or behavior. In 1989, approximately one year after the initial strengthening, the bridge was retested to identify any changes in its behavior. Post-tensioning forces were removed to reveal any losses over the one-year period. Post-tensioning was reapplied to the bridge, and the bridge was tested using the same loading program used in 1988. Except for at a few locations, stresses were reduced in the bridge the desired amount. At a few locations flexural stresses in the steel beams are still above 18 ksi, the allowable inventory stress for A7 steel. Although maximum stresses are above the inventory stress by about 2 ksi, they are about 5 ksi below the allowable operating stress; therefore, the bridge no longer needs to be load-posted.

Bond Enhancement Techniques for PCC Whitetopping, HR-341, 1996

This research was initiated in 1991 as a part of a whitetopping project to study the effectiveness of various techniques to enhance bond strength between a new portland cement concrete (PCC) overlay and an existing asphalt cement concrete (ACC) pavement surface. A 1,676 m (5,500 ft) section of county road R16 in Dallas County was divided into 12 test sections. The various techniques used to enhance bond were power brooming, power brooming with air blast, milling, cement and water grout, and emulsion tack coat. Also, two sections were planed to a uniform cross-section, two pavement thicknesses were placed, and two different concrete mix proportions were used. Bond strength was perceived to be the key to determining an appropriate design procedure for whitetopping. If adequate bond is achieved, a bonded PCC overlay technique can be used for design. Otherwise, an unbonded overlay procedure may be more appropriate. Conclusions are as follows: (1) Bond Strength Differences - Milling increased bond strength versus no milling. Tack coat showed increased bond strength versus no tack coat. Planing, Air Blast and Grouting did not provide noticeable improvements in bond strength; nor did different PCC types or thicknesses affect bond strength significantly. (2) Structure - Structural measurements correlated strongly with the wide variation in pavement thicknesses. They did not provide enough information to determine the strength of bonding or the level of support being provided by the ACC layer. Longitudinal cracking correlated with PCC thicknesses and with planing. (3) Bond Over Time - The bond between PCC and ACC layers is degrading over time in the outside wheel path in all of the sections except tack coat (section 12). The bond strength in the section with tack coat was lower than the others, but remained relatively steady.

Dynamic Deflections to Determine Roadway Support Ratings, HR-245, 1983

The Benkelman Beam structural test of flexible pavements was replaced in 1976 by dynamic deflection testing with a model 400 Road Rater. The Road Rater is used to determine structural ratings of flexible pavements. New pavement construction in Iowa has decreased with a corresponding increase of restoration and rehabilitation. A method to determine structural ratings of layered systems and rigid pavements is needed to properly design overlay thickness. The objective of this research was to evaluate the feasibility of using the Road Rater to determine support values of layered systems and rigid pavements. This evaluation was accomplished by correlating the Road Rater with the Federal Highway Administration (FHWA) Thumper, a dynamic deflection testing device. Data were obtained with the Road Rater and Thumper at 411 individual test locations on 39 different structural sections ranging from 10" of PCC pavement and 25" of asphalt pavement to a newly graveled unpaved roadway. A high correlation between a 9000 pound Thumper deflection and the 1185 pound Road Rater deflection was obtained. A Road Rater modification has been completed to provide 2000 pound load inputs. The basin, defined by four sensors spaced at 1 foot intervals, resulting from the 2000 pound loading is being used to develop a graph for determining relative subgrade strengths. Road Rater deflections on rigid pavements are sufficient to support the potential for this technique.