Control of Concrete Deterioration Due to Trace Compounds in Deicers, Phase II, HR-299, 1989

This report presents results of research on ways to reduce the detrimental effects of sulfate-tainted rock salt deicers on portland cement concrete used for highway pavements. Repetitious experiments on the influence of fly ash on the mortar phase of concrete showed significant improvement in resistance to deicing brines is possible. Fifteen to twenty percent by weight of fly ash replacement for portland cement was found to provide optimum improvement. Fly ashes from five sources were evaluated and all were found to be equally beneficial. Preliminary results indicate the type of coarse aggregate also plays an important role in terms of concrete resistance to freeze-thaw in deicing brines. This was particularly true for a porous ferroan dolomite thought to be capable of reaction with the brine. In this case fly ash improved the concrete, but not enough for satisfactory performance. An intermediate response was with a porous limestone where undesirable results were observed without fly ash and adequate performance was realized when 15% fly ash was added. The best combination for making deicer-resistant concrete was found to be with a non-porous limestone. Performance in brines was found to be adequate without fly ash, but better when fly ash was included. Consideration was given to treating existing hardened concrete made with poor aggregate and no fly ash to extend pavement life in the presence of deicers, particularly at joints. Sodium silicate was found to improve freeze-thaw resistance of mortar and is a good candidate for field usage because of its low cost and ease of handling.

Evaluation of the Concrete Admixture Gla-Zit, MLR-81-5, 1983

A concrete admixture, Gla-Zit, was evaluated in 1970 by the Iowa State Highway Commission and found to be lacking in providing beneficial effects to concrete. This current evaluation is similar to that conducted in 1970 with slight modifications in the actual concrete mixes studied. At the request of the manufacturer, all concrete mixes containing Gla-Zit were non-air entrained. Concrete properties examined were compressive strength, salt scaling resistance, absorption, resistance to chloride penetration, and freeze-thaw durability. The differences found in the mixes studied are much more attributible to air entrainment, or the lack thereof, than the influence of Gla-Zit. The study re-affirms that it is necessary to have properly air entrained concrete to lessen the detrimental effects of freeze and thaw and scaling caused by salting. There is no data in the study to suggest that Gla-Zit has any significant effect on any of the concrete properties examined.

Laboratory Evaluation of Roller-Compacted Concrete, MLR-86-6, 1988

Fine limestone aggregate is abundant in several areas of the state. The aggregate is a by-product from the production of concrete stone. Roller compacted concrete (RCC) is a portland cement concrete mixture that can be produced with small size aggregate. The objective of the research was to evaluate limestone screenings in RCC mixes. Acceptable strength and freeze/thaw durability were obtained with 300 pounds of portland cement and 260 pounds of Class C fly ash. The amount of aggregate passing the number 200 sieve ranged from 4.6 to 11 percent. Field experience in Iowa indicates that the aggregate gradation is more critical to placeability and compactibility than laboratory strength and durability.

Special Cements for Fast Track Concrete, MLR-87-4, 1988

Two specialty cements are currently being marketed as a way to achieve portland cement concrete pavement opening strengths at less than 12 hours after placement. The cements are Pyrament from Pyrament/Lone Star Industries of Houston, Texas and Ideal Regulated-Set (RS) Portland Cement from Ideal Cement Company of Saratoga, Arkansas. The objective of the study was to evaluate the strength gain and durability of concrete produced with Pyrament and Ideal RS cement as Fast Track concrete. Mixes with 610 lb/cu yd (362 kg/cu m) cement were made and tested. Both Pyrament and Ideal RS are capable of producing pavement opening times less than 12 hours. Recent changes to Ideal RS cement have produced concrete flexural strengths of 550 psi (3792 kPa) at 4 hours in Iowa tests. Freeze/thaw durability of the concrete was not adversely affected by using either cement.

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.

Deterioration of Iowa Highway Concrete Pavements: A Petrographic Study, HR-1065, 1999

Major highway concrete pavements in Iowa have exhibited premature deterioration attributed to effects of ettringite formation, alkali-silica expansive reactions, and to frost attack, or some combination of them. These pavements were constructed in the mid- 1980s as non-reinforced, dual-lane, roads ranging in thickness between 200 mm and 300 mm, with skewed joints reinforced with dowels. Deterioration was initially recognized with a darkening of joint regions, which occurred for some pavements as soon as four years after construction. Pavement condition ranges from severe damage to none, and there appeared to be no unequivocal materials or processing variables correlated with failure. Based upon visual examinations, petrographic evaluation, and application of materials models, the deterioration of concrete highway pavements in Iowa appear related to a freeze-thaw failure of the coarse aggregate and the mortar. Crack patterns sub-parallel to the concrete surface transecting the mortar fraction and the coarse aggregate are indicative of freeze-thaw damage of both the mortar and aggregate. The entrained air void system was marginal to substandard, and filling of some of the finer-sized voids by ettringite appears to have further degraded the air void system. The formation of secondary ettringite within the entrained air voids probably reflects a relatively high degree of concrete saturation causing the smaller voids to be filled with pore solution when the concrete freezes. Alkali-silica reaction (ASR) affects some quartz and shale in the fine aggregate, but is not considered to be a significant cause of the deterioration. Delayed ettringite formation was not deemed likely as no evidence of a uniform paste expansion was observed. The lack of field-observed expansion is also evidence against the ASR and DEF modes of deterioration. The utilization of fly ash does not appear to have affected the deterioration as all pavements with or without fly ash exhibiting substantial damage also exhibit significant filling of the entrained air void system, and specimens containing fly ash from sound pavements do not have significant filling. The influence of the mixture design, mixing, and placing must be evaluated with respect to development of an adequate entrained air void system, concrete homogeneity, longterm drying shrinkage, and microcracking. A high-sand mix may have contributed to the difficult mixture characteristics noted upon placement and exacerbate concrete heterogeneity problems, difficulty in developing an adequate entrained air void system, poor consolidation potential, and increased drying shrinkage and cracking. Finally, the availability of moisture must also be considered, as the secondary precipitation of ettringite in entrained air voids indicates they were at least partially filled with pore solution at times. Water availability at the base of the slabs, in joints, and cracks may have provided a means for absorbing water to a point of critical saturation.

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.

Air Content and Permeability of PCC Pavements: 1909 to 2006, MLR-05-02, 2007

Portland cement concrete pavements have given excellent service history for Iowa. Many of these pavements placed during the 1920’s and 1930’s are still in service today. Many factors go in to achieve a long term durable concrete pavement. Probably the most important is the durability of the aggregate. Until the 1930’s, pit run gravel was the most predominant aggregate used. Many of these gravels provided long term performance and their durability is dependent upon the carbonate fraction of the gravel. Later, limestone (calcium carbonate) and dolomite (calcium, magnesium carbonate) sources were mined across Iowa. The durability of these carbonate aggregates is largely dependent upon the pore system which can cause freeze thaw problems known as D-cracking, which was a problem with some sources during the 1960’s. Also, some of these carbonate aggregates are also susceptible to deterioration from deicing salts. Geologists have identified the major components that affect the durability of these carbonate aggregates and sources are tested to ensure long term performance in Portland cement concrete. Air entrainment was originally put in concrete to improve scaling resistance. It is well known that air entrainment is required to provide freeze thaw protection in concrete pavements today. In Iowa, air entrainment was not introduced in concrete pavements until 1952. This research investigates properties that made older concrete pavements durable without air entrainment.

Reduction of Concrete Deterioration by Ettringite Using Crystal Growth Inhibition Techniques: Part II Field Evaluation of Inhibitor Effectiveness, TR-469, 2004

The effects of diethylenetriaminpenta(methylenephosphonic acid) (DTPMP), a phosphonate inhibitor, on the growth of delayed ettringite have been evaluated using concrete in highway US 20 near Williams, Iowa, and the cores of six highways subject to moderate (built in 1992) or minor (built in 1997) deterioration. Application of 0.01 and 0.1 vol. % DTPMP to cores was made on a weekly or monthly basis for one year under controlled laboratory-based freeze-thaw and wet-dry conditions over a temperature range of -15 degrees to 58 degrees C to mimic extremes in Iowa roadway conditions. The same concentrations of phosphonate were also applied to cores left outside (roof of Science I at Iowa State University) over the same period of time. Nineteen applications of 0.1 vol. % DTPMP with added deicing salt solution (about 23 weight % NACL) were made to US 20 during the winters of 2003 and 2004. In untreated samples, air voids, pores, and occasional cracks are lined with acicular ettringite crystals (up to 50 micrometers in length) whereas air voids, pores, and cracks in concrete from the westbound lane of US 20 are devoid of ettringite up to a depth of about 0.5 mm from the surface of the concrete. Ettringite is also absent in zones up to 6 mm from the surface of concrete slabs placed on the roof of Science I and cores subject to laboratory-based freeze-thaw experiments. In these zones, the relatively high concentration of DTPMP caused it to behave as a chelator. Stunted ettringite crystals 5 to 25 micrometers in length, occasionally coated with porlandite, form on the margins of these zones indicating that in these areas DTPMP behaved as an inhibitor due to a reduction in the concentration of phosphonate. Analyses of mixes of ettringite and DTPMP using electrospray mass spectrometry suggests that the stunting of ettringite growth is caused by the adsorption of a Ca2+ ion and a water molecule to deprotonated DTPMP on the surface of the {0001} face of ettringite. It is anticipated that by using a DTPMP concentration of between 0.001 and 0.01 vol. % for the extended life of a highway (i.e. >20 years), deterioration caused by the expansive growth of ettringite will be markedly reduced.

Biofuel Co-Product Uses for Pavement Geo-Materials Stabilization, TR-582, 2010

The production and use of biofuels has increased in the present context of sustainable development. Biofuel production from plant biomass produces not only biofuel or ethanol but also co-products containing lignin, modified lignin, and lignin derivatives. This research investigated the utilization of lignin-containing biofuel co-products (BCPs) in pavement soil stabilization as a new application area. Laboratory tests were conducted to evaluate the performance and the moisture susceptibility of two types of BCP-treated soil samples compared to the performance of untreated and traditional stabilizer-treated (fly ash) soil samples. The two types of BCPs investigated were (1) a liquid type with higher lignin content (co-product A) and (b) a powder type with lower lignin content (co-product B). Various additive combinations (co-product A and fly ash, co-products A and B, etc.) were also evaluated as alternatives to stand-alone co-products. Test results indicate that BCPs are effective in stabilizing the Iowa Class 10 soil classified as CL or A-6(8) and have excellent resistance to moisture degradation. Strengths and moisture resistance in comparison to traditional additives (fly ash) could be obtained through the use of combined additives (co-product A + fly ash; co-product A + co-product B). Utilizing BCPs as a soil stabilizer appears to be one of the many viable answers to the profitability of the bio-based products and the bioenergy business. Future research is needed to evaluate the freeze-thaw durability and for resilient modulus characterization of BCP-modified layers for a variety of pavement subgrade and base soil types. In addition, the long-term performance of these BCPs should be evaluated under actual field conditions and traffic loadings. Innovative uses of BCP in pavement-related applications could not only provide additional revenue streams to improve the economics of biorefineries, but could also serve to establish green road infrastructures.

Determination and Evaluation of Alternate Methods for Managing and Controlling Highway-Related Dust, TR-449, 2002

Road dust is caused by wind entraining fine material from the roadway surface and the main source of Iowa road dust is attrition of carbonate rock used as aggregate. The mechanisms of dust suppression can be considered as two processes: increasing particle size of the surface fines by agglomeration and inhibiting degradation of the coarse material. Agglomeration may occur by capillary tension in the pore water, surfactants that increase bonding between clay particles, and cements that bind the mineral matter together. Hygroscopic dust suppressants such as calcium chloride have short durations of effectiveness because capillary tension is the primary agglomeration mechanism. Somewhat more permanent methods of agglomeration result from chemicals that cement smaller particles into a mat or larger particles. The cements include lignosulfonates, resins, and asphalt products. The duration of the cements depend on their solubility and the climate. The only dust palliative that decreases aggregate degradation is shredded shingles that act as cushions between aggregate particles. It is likely that synthetic polymers also provide some protection against coarse aggregate attrition. Calcium chloride and lignosulfonates are widely used in Iowa. Both palliatives have a useful duration of about 6 months. Calcium chloride is effective with surface soils of moderate fine content and plasticity whereas lignin works best with materials that have high fine content and high plasticity indices. Bentonite appears to be effective for up to two years and works well with surface materials having low fines and plasticity and works well with limestone aggregate. Selection of appropriate dust suppressants should be based on characterization of the road surface material. Estimation of dosage rates for potential palliatives can be based on data from this report, from technical reports, information from reliable vendors, or laboratory screening tests. The selection should include economic analysis of construction and maintenance costs. The effectiveness of the treatment should be evaluated by any of the field performance measuring techniques discussed in this report. Novel dust control agents that need research for potential application in Iowa include; acidulated soybean oil (soapstock), soybean oil, ground up asphalt shingles, and foamed asphalt. New laboratory evaluation protocols to screen additives for potential effectiveness and determine dosage are needed. A modification of ASTM D 560 to estimate the freeze-thaw and wet-dry durability of Portland cement stabilized soils would be a starting point for improved laboratory testing of dust palliatives.

Fly Ash Soil Stabilization for Non-Uniform Subgrade Soils, Volume I: Engineering Properties and Construction Guidelines, TR-461, 2005

Soil treated with self-cementing fly ash is increasingly being used in Iowa to stabilize fine-grained pavement subgrades, but without a complete understanding of the short- and long-term behavior. To develop a broader understanding of fly ash engineering properties, mixtures of five different soil types, ranging from ML to CH, and several different fly ash sources (including hydrated and conditioned fly ashes) were evaluated. Results show that soil compaction characteristics, compressive strength, wet/dry durability, freeze/thaw durability, hydration characteristics, rate of strength gain, and plasticity characteristics are all affected by the addition of fly ash. Specifically, Iowa selfcementing fly ashes are effective at stabilizing fine-grained Iowa soils for earthwork and paving operations; fly ash increases compacted dry density and reduces the optimum moisture content; strength gain in soil-fly ash mixtures depends on cure time and temperature, compaction energy, and compaction delay; sulfur contents can form expansive minerals in soil–fly ash mixtures, which severely reduces the long-term strength and durability; fly ash increases the California bearing ratio of fine-grained soil–fly ash effectively dries wet soils and provides an initial rapid strength gain; fly ash decreases swell potential of expansive soils; soil-fly ash mixtures cured below freezing temperatures and then soaked in water are highly susceptible to slaking and strength loss; soil stabilized with fly ash exhibits increased freeze-thaw durability; soil strength can be increased with the addition of hydrated fly ash and conditioned fly ash, but at higher rates and not as effectively as self-cementing fly ash. Based on the results of this study, three proposed specifications were developed for the use of self-cementing fly ash, hydrated fly ash, and conditioned fly ash. The specifications describe laboratory evaluation, field placement, moisture conditioning, compaction, quality control testing procedures, and basis of payment.

Low-Cost Rural Surface Alternatives: Demonstration Project, TR-664, 2015

The goals of this project were to implement several stabilization methods for preventing or mitigating freeze-thaw damage to granular surfaced roads and identify the most effective and economical methods for the soil and climate conditions of Iowa. Several methods and technologies identified as potentially suitable for Iowa were selected from an extensive analysis of existing literature provided with Iowa Highway Research Board (IHRB) Project TR-632. Using the selected methods, demonstration sections were constructed in Hamilton County on a heavily traveled two-mile section of granular surfaced road that required frequent maintenance during previous thawing periods. Construction procedures and costs of the demonstration sections were documented, and subsequent maintenance requirements were tabulated through two seasonal freeze-thaw periods. Extensive laboratory and field tests were performed prior to construction, as well as before and after the two seasonal freeze-thaw periods, to monitor the performance of the demonstration sections. A weather station was installed at the project site and temperature sensors were embedded in the subgrade to monitor ground temperatures up to a depth of 5 ft and determine the duration and depths of ground freezing and thawing. An economic analysis was performed using the documented construction and maintenance costs, and the estimated cumulative costs per square yard were projected over a 20-year timeframe to determine break-even periods relative to the cost of continuing current maintenance practices. Overall, the sections with biaxial geogrid or macadam base courses had the best observed freeze-thaw performance in this study. These two stabilization methods have larger initial costs and longer break-even periods than aggregate columns, but counties should also weigh the benefits of improved ride quality and savings that these solutions can provide as excellent foundations for future paving or surface upgrades.

Cement Stabilization of Embankment Materials, 2015

Embankment subgrade soils in Iowa are generally rated as fair to poor as construction materials. These soils can exhibit low bearing strength, high volumetric instability, and freeze/thaw or wet/dry durability problems. Cement stabilization offers opportunities to improve these soils conditions. The objective of this study was to develop relationships between soil index properties, unconfined compressive strength and cement content. To achieve this objective, a laboratory study was conducted on 28 granular and non-granular materials obtained from 9 active construction sites in Iowa. The materials consisted of glacial till, loess, and alluvium sand. Type I/II portland cement was used for stabilization. Stabilized and unstabilized specimens were prepared using Iowa State University 2 in. by 2 in. compaction apparatus. Specimens were prepared, cured, and tested for unconfined compressive strength (UCS) with and without vacuum saturation. Percent fines content (F200), AASHTO group index (GI), and Atterberg limits were tested before and after stabilization. The results were analyzed using multi-variate statistical analysis to assess influence of the various soil index properties on post-stabilization material properties. Results indicated that F200, liquid limit, plasticity index, and GI of the materials generally decreased with increasing cement content. The UCS of the stabilized specimens increased with increasing cement content, as expected. The average saturated UCS of the unstabilized materials varied between 0 and 57 psi. The average saturated UCS of stabilized materials varied between 44 and 287 psi at 4% cement content, 108 and 528 psi at t 8% cement content, and 162 and 709 psi at 12% cement content. The UCS of the vacuum saturated specimens was on average 1.5 times lower than that of the unsaturated specimens. Multi-variate statistical regression models are provided in this report to predict F200, plasticity index, GI, and UCS after treatment, as a function of cement content and soil index properties.

Sewage Sludge Electro-Dewatering

Original sludge from wastewater treatment plants (WWTPs) usually has a poor dewaterability. Conventionally, mechanical dewatering methods are used to increase the dry solids (DS) content of the sludge. However, sludge dewatering is an important economic factor in the operation of WWTPs, high water content in the final sludge cake is commonly related to an increase in transport and disposal costs. Electro‐dewatering could be a potential technique to reduce the water content of the final sludge cake, but the parameters affecting the performance of electro‐dewatering and the quality of the resulting sludge cake, as well as removed water, are not sufficiently well known. In this research, non‐pressure and pressure‐driven experiments were set up to investigate the effect of various parameters and experimental strategies on electro‐dewatering. Migration behaviour of organic compounds and metals was also studied. Application of electrical field significantly improved the dewatering performance in comparison to experiments without electric field. Electro‐dewatering increased the DS content of the sludge from 15% to 40 % in non‐pressure applications and from 8% to 41% in pressure‐driven applications. DS contents were significantly higher than typically obtained with mechanical dewatering techniques in wastewater treatment plant. The better performance of the pressure‐driven dewatering was associated to a higher current density at the beginning and higher electric field strength later on in the experiments. The applied voltage was one of the major parameters affecting dewatering time, water removal rate and DS content of the sludge cake. By decreasing the sludge loading rate, higher electrical field strength was established between the electrodes, which has a positive effect on an increase in DS content of the final sludge cake. However interrupted voltage application had anegative impact on dewatering in this study, probably because the off‐times were too long. Other factors affecting dewatering performance were associated to the original sludge characteristics and sludge conditioning. Anaerobic digestion of the sludge with high pH buffering capacity, polymer addition and freeze/thaw conditioning had a positive impact on dewatering. The impact of pH on electro‐dewatering was related to the surface charge of the particles measured as zeta‐potential. One of the differences between electro‐dewatering and mechanical dewatering technologies is that electro‐dewatering actively removes ionic compounds from the sludge. In this study, dissolution and migration of organic compounds (such as shortchain fatty acids), macro metals (Na, K, Ca, Mg, Fe) and trace metals (Ni, Mn, Zn, Cr) was investigated. The migration of the metals depended on the fractionation and electrical field strength. These compounds may have both negative and positive impacts on the reuse and recycling of the sludge and removed water. Based on the experimental results of this study, electro‐dewatering process can be optimized in terms of dewatering time, desired DS content, power consumption and chemical usage.