Search

A recent development in polymer concrete overlays is the Cargill SafeLane surface overlay (SafeLane overlay). The 3/8-in-thick overlay is constructed with epoxy and broadcast aggregates, as are typical multiple-layer epoxy overlays that are used to provide a skid-resistant wearing surface for bridge decks that protects the decks again intrusion by chloride ions. Reportedly, the SafeLane overlay is unique in that Cargill indicates that the limestone aggregate used in the overlay can absorb and store liquid deicing chemicals that are applied to the surface of the roadway. The purpose of this research was to compare the SafeLane overlay and the Virginia Department of Transportation (VDOT) modified EP-5 epoxy concrete overlay (hereinafter called the VDOT modified EP-5 overlay) based on an evaluation of their construction, initial condition, and effectiveness in preventing frost, ice, and snow formation on the surface of the roadway. The comparison was limited to overlays placed on four bridges on I-81 in 2004 and 2005 (two SafeLane and two VDOT modified EP-5 overlays) and on four sections of continuously reinforced concrete pavement on the Virginia Smart Road in 2006. The evaluation with respect to the initial condition of the overlays on I-81 was based on a comparison of the as-constructed properties, including aggregate properties, bond strength, permeability, skid resistance, and chloride content. The evaluation with respect to the initial condition of the overlays on the Smart Road was limited to skid resistance. The evaluation of the overlays with respect to their effectiveness in preventing frost, ice, and snow formation was based on visual observations and skid measurements of overlay surfaces under typical interstate winter conditions at the I-81 sites and under artificial snow and ice conditions at the Smart Road. In addition, the effectiveness of the overlays at the Smart Road in preventing frost, ice, and snow formation was compared with that of a bare-tined concrete surface. The evaluation indicated that the SafeLane overlay can provide a skid-resistant wearing and protective surface for bridge decks. The study was not able to determine the performance of the overlay with respect to providing a surface with less accumulation of ice and snow. Further, there has not been sufficient time to evaluate chloride penetration into the decks overlaid with SafeLane overlays in Virginia. Virginia Department of Transportation 78408

This project reviewed existing laboratory methods for accurately describing the constitutive behavior of the mixes used in the Commonwealth of Virginia. Indirect tensile (IDT) strength, resilient modulus, static creep in the IDT and uniaxial modes, flexural beam fatigue, and dynamic modulus tests were conducted on two typical mixes used in Virginia: SM-9.5A (surface mix) and BM-25.0 (base mix). The tests conducted produced a wealth of data on typical values for the properties of the two mixes studied over a wide range of temperatures and loading frequencies. The results suggest that the IDT strength test is an effective test to characterize the tensile strength of hot-mix asphalt (HMA), especially for thermal cracking evaluation. The resilient modulus test and the static creep test in the IDT setup are practical and simple to perform, but the analysis of the measurements is complicated, and the variability of the results is high. The compressive uniaxial dynamic modulus and the uniaxial static creep tests were found to be simple to conduct and to analyze because of the homogeneous state of stress in the specimen during testing. The flexural fatigue test was time consuming, but the test produces valuable information about the fatigue properties of hot-mix asphalt. The investigation also found good correlations among the IDT strength, resilient modulus, and dynamic modulus results. A variety of tests is recommended for characterizing the mechanistic-empirical pavement analysis and design. These tests would provide the properties needed to characterize the asphalt layers for the pavement analysis and design. The recommended tests are as follows: IDT strength for characterizing HMA susceptibility to thermal cracking, dynamic modulus for characterization of the constitutive behavior of the HMA, uniaxial creep for characterizing permanent deformation characteristics, and flexural fatigue tests to characterize fatigue properties. Materials characterization testing can be a valuable tool in pavement design. The use of mechanistic-empirical modeling can be used to predict the performance of a pavement. With this type of testing and modeling, the materials used in pavements will be of better quality and more resistant to environmental and structural deterioration. A more durable pavement will aid in reducing the frequency and costs associated with maintenance. Virginia Department of Transportation 70984

Concrete experiences volume changes throughout its service life. When loaded, concrete experiences an instantaneous recoverable elastic deformation and a slow inelastic deformation called creep. Creep of concrete is composed of two components, basic creep, or deformation under load without moisture loss and drying creep, or deformation under drying conditions only. Deformation of concrete in the absence of applied load is often called shrinkage. The deformation due to creep is attributed to the movement of water between the different phases of the concrete. When an external load is applied, it changes the attraction forces between the cement gel particles. This change in the forces causes an imbalance in the attractive and disjoining forces. However, the imbalance is gradually eliminated by the transfer of moisture into the pores in cases of compression, and away from the pores in cases of tension. Designs typically use one of the two code models to estimate creep and shrinkage strain in concrete, ACI 209 model recommended by the American Concrete Institute or the CEB 90 Eurocode 2 model recommended by the Euro-International Committee. The AASHTO LRFD is based on the ACI 209 model. Three other models are the B3 model, developed by Bazant; the GZ model, developed by Gardner; and the SAK model developed by Sakata. The objectives of this research was the development of performance limits for compressive creep of concrete mixtures used by the Virginia Department of Transportation, specifically concrete mixtures used for prestressed members (A-5 Concrete) and the determination the accuracy and precision of the creep models presented in the literature. The CEB 90 Eurocode 2 model for creep and shrinkage is the most precise and accurate predictor. The total creep strain for the VDOT portland cement concrete mixtures discussed in this study were found to be between 1200 +/- 110 microstrain at 28 days, and 1600 +/- 110 microstrain at 97 days, at a five percent significant level. It is recommended that the CEB 90 model be used in the AASHTO LRFD rather than the ACI 209 model to improve the prediction of prestress loss. Virginia Department of Transportation

Chloride-ion-induced corrosion of reinforcing steel in concrete bridge decks has become a major problem in the United States. Latex-modified concrete, low-slump dense concrete, and hot-mix asphalt membrane overlays are some of the most used rehabilitation methods. Epoxy-coated reinforcing steel was developed and promoted as a long-term corrosion protection method by the Federal Highway Administration. However, recent evidence has suggested that epoxy-coated reinforcing steel will not provide adequate long-term corrosion protection. The Reynolds Metals Company developed an aluminum bridge deck system as a proposed alternative to conventional reinforced steel bridge deck systems. The deck consists of a polymer concrete overlay and an aluminum substrate. The purpose of this investigation was to evaluate the bond durability between the overlay and the aluminum substrate after specimens were conditioned in various temperature and humidity conditions. The different environmental conditionings all had a significant effect on the bond durability. Specimens conditioned at 30C, 45 C, and 60C at 98 percent relative humidity all showed a decrease in interfacial bond strength after conditioning. There was also a decrease in the interfacial bond strength for the specimens conditioned in freezing and thawing cycles and specimens conditioned in a salt water soak. The only exposure condition that increased the bond strength was drying the specimens continuously in an oven at 60C. Virginia Department of Transportation 21558 FHWA 21558

In this study, the corrosion protection performance of epoxy-coated reinforcing steel (ECR) was evaluated using approximately 250 concrete cores from 18 bridge decks in Virginia. The decks were 2 to 20 years old at the time of the investigation. The deck field inspections included a crack survey and cover depth determination in the right traffic lane. A maximum of 12 cores with the top reinforcement randomly located in the lowest 12th percentile cover depth were taken from each bridge deck. Because of the safety concerns associated with taking cores from the lower steel mat, and to minimize damage to the bridge, a maximum of only 3 cores were taken through the truss bars. The laboratory evaluation of the concrete cores included a visual examination and a determination of the carbonation depth, moisture content, absorption, percent saturation, and chloride content at a 13-mm depth. The rapid chloride permeability test was also performed for the surface and base concrete on samples obtained from the cores taken through the truss bars to determine chloride permeability. The ECR inspection consisted of a visual examination, a damage evaluation, and a determination of coating thickness and adhesion. The condition of the steel underneath the epoxy coating was also evaluated. Adhesion loss of the epoxy coating to the steel surface was detected in all but one deck that was 4 years old and older. The epoxy coatings were debonding from the reinforcing bars. Whereas a bonded coating can be expected to protect the steel, a debonded coating allows chlorides, moisture, and oxygen to reach the steel and initiate a rapid corrosion mechanism. Reinforcing bars in various stages of adhesion loss showed visible signs of a corrosion process underneath the coating, suggesting that ECR will provide little or no additional service life for concrete bridge decks in comparison to bare steel. Other systems that will provide longer protection against chloride-induced corrosion of the reinforcing steel with a higher degree of reliability should be considered. Virginia Department of Transportation