Performance of Polymer Modified Asphalt Bridge Expansion Joints in Low-Temperature Regions

Conventional asphalt bridge expansion joints used in low-temperature regions generally show cracking within the first 2?years. To improve the low-temperature performance of these joints, the commercial MEIJIA asphalt binder commonly used in bridge expansion joint construction was modified with two polymers: thermoplastic rubber and rubber. The goal is to find an optimum combination of polymers, binders, and aggregates to improve the performance of asphalt expansion joints in low-temperature regions. The polymer modified binders and mixtures were evaluated for their low-temperature properties using ductility, penetration, indirect tension, and bending tests. The study indicates that performance of these joints at low temperature can be enhanced significantly with the right combinations of polymers, binders, and aggregates. Four expansion joints made with the polymer modified asphalt mixtures were installed on two bridges in a cold region. A construction procedure was also developed to install these joints properly to minimize low-temperature cracking along the interface between the joint and bridge deck. After 7?years of service, the four joints show good performance without any visible cracking or rutting.     

Utilizing Advanced Characterization Tools to Prevent Reflective Cracking

To prevent premature failures of rehabilitated concrete pavements, transportation authorities need tools to characterize the prerehab pavement condition of its load carrying capacity, and to determine the resistance of the overlay material to underlying crack/joint movements. Two quantitative methods, the rolling dynamic deflectometer (RDD) and overlay tester (OT), along with field performance data were employed in rehabilitation studies involving reflective cracks. The RDD is able to continuously assess vertical differential movements at joints/cracks that represent the potential for reflective cracks on existing pavements. The OT has the ability to determine the resistance of the overlay material to underlying crack/joint movements. The RDD W1?W3 deflections were used to determine areas that have a high potential for reflective cracking due to poor load transfer across joints and cracks. This paper documents results from the RDD and OT on the following five rehabilitation projects: (1) SH225; (2) US96; (3) SH12; (4) SH342; and (5) IH35W. Based on the available test results from these five projects, it was observed that the W1?W3 threshold values of 5.5 mils (0.140 mm) for exposed concrete pavement and 6.5 mils (0.165 mm) for composite pavement with existing hot mix asphalt overlay and an OT threshold value of 700 cycles correlated well with the field performance. Ignoring either of these critical factors may lead to premature reflective cracking.     

“Underlying” Causes for Settlement of Bridge Approach Pavement Systems

A comprehensive field study of 74 bridges in Iowa was conducted to characterize problems leading to poor performance of bridge approach pavement systems. Subsurface void development caused by water infiltration through unsealed expansion joints, collapse and erosion of the granular backfill, and poor construction practices were found to be the main contributing factors. To characterize the problem, International Roughness Index and profile measurements from several sites were used to show that approach pavement roughness is several times higher than the average roadway condition and are most severe at the abutment-to-approach pavement intersection and transverse expansion joints due to large (5–10?cm) joint widths. Further, a settlement time history was documented at one bridge site by measuring the approach slab pavement elevations periodically after completion of bridge construction, revealing a progressive settlement problem under the approach pavement. To better understand the void development under the approach pavement, laboratory compaction tests were performed on granular backfill materials from various bridge sites to quantify their saturated collapse potential in the postconstruction phase. These tests revealed collapse potential of backfill materials in the range of 5–18% (based on volume) with the high values for poorly graded sandy backfill materials, indicating significant settlement problems. Based on the research findings, some relatively simple design and construction modifications are suggested which could be used to alleviate field problems for similar bridge approach pavement systems.     

Investigation of Settlement of a Jointed Concrete Pavement

A section of jointed concrete pavement on U.S. 75, which was built from 1982 to 1985, in the Paris District of the Texas Department of Transportation (TxDOT) experienced severe pumping and settlement, even though two types of treatment (full depth repair and polyurethane foam injection) were performed. An extensive field investigation was conducted using ground penetrating radar, falling weight deflectometer, dynamic cone penetrometer, and coring to identify the causes of the continued pumping and settlement problems, and develop an optimal repair strategy. The pavement evaluation included tie bar condition, load transfer efficiency (LTE) at transverse and longitudinal construction joints, and base support conditions. Some of the tie bars failed in shear due to corrosion, which resulted in substantially low LTEs (<40%) at longitudinal construction joints. Pumping and settlement problems were more pronounced where the tie bars failed; the resulting large deflections exacerbated the pumping and settlement problems. The results demonstrate the importance of adequate LTEs (>80%) provided by tie bars, base and subgrade support, in providing satisfactory JCP performance. Inadequate design or construction of any of these critical elements could lead to performance problems, potentially including severe settlement, which is quite difficult to repair. To repair this pavement section, the Paris District of TxDOT is planning to retrofit tie bars by the “slot stitching” method, along with filling the voids under the slab using grout, followed by thin overlay using latex modified concrete to correct the differential elevation problems at longitudinal construction joints. It is expected that this repair strategy will address the distress problems and extend the pavement life.     

Investigation of Permeability on Indiana SR-38

In 1999, a 9.5 mm nominal maximum size hot-mix asphalt mixture, designed according to the Superpave mixture design method, was placed as an overlay on Indiana State Road 38. Within one year of construction, the pavement showed signs of significant distress, including aggregate pop-outs and degradation, the presence of free water (weeping) on the driving surface, and longitudinal and fatigue cracking. At the request of the District, an investigation was undertaken to determine the cause of the pavement distress. As part of the investigation, core samples were taken from the roadway surface and tested for compliance with material properties and volumetrics, and to determine the mixture permeability. The mixture met all applicable materials and volumetric specifications, but had a low in-place density and was permeable. The results indicate that the mixture was too coarsely graded to achieve compaction in the relatively thin lift specified by the Department of Transportation. The resulting recommendations were that the mixture be removed and replaced, and that the mixture specifications be revised to more closely control gradation and increase mixture lift thickness.     

Improved Longitudinal Joint Details in Decked Bulb Tees for Accelerated Bridge Construction: Concept Development

This paper focuses on an investigation of improved continuous longitudinal joint details for decked precast prestressed concrete girder bridge systems. Precast concrete girders with an integral deck that is cast and prestressed with the girder provide benefits of rapid construction along with improved structural performance and durability. Despite these advantages, use of this type of construction has been limited to isolated regions of the United States. One of the issues limiting more widespread use is a perceived problem with durability of longitudinal joints used to connect adjacent girders. This paper presents the results of a study to assess potential alternate joint details based on constructability, followed by testing of selected details. Seven reinforced concrete beam specimens connected with either lapped headed reinforcement or lapped welded wire reinforcement were tested along with a specimen reinforced by continuous bars for comparison. Test results were evaluated based on flexural capacity, curvature at failure, cracking, deflection, and steel strain. Based on the survey and the experimental program, a headed bar detail with a 152 mm (6 in.) lap length was recommended for replacing the current welded steel connector detail.     

Field Investigations of Cracking on Concrete Pavements

This paper presents the results of several investigations to identify the underlying causes of longitudinal cracking problems in Portland cement concrete (PCC) pavement. Longitudinal cracking is not intended and detrimental to the long-term performance of PCC pavement. Longitudinal cracking problems in five projects were thoroughly investigated and the findings indicate that longitudinal cracking was caused by: (1) late or shallow saw cutting of longitudinal joints; (2) inadequate base support under the concrete slab; and (3) the use of high coefficient of thermal expansion (CTE) aggregates. When the longitudinal cracks were caused by late or shallow saw cutting of longitudinal joints, cracks developed at a very early stage. However, when there was adequate base support, the longitudinal cracks remained relatively tight even after decades of truck trafficking. Another cause of longitudinal cracking was inadequate base support, and cracking due to this mechanism normally progressed to rather wide cracks. Some cracks were as wide as 57?mm. Evaluations of base support by dynamic cone penetrometer in areas where longitudinal cracks were observed indicate quite weak subbase in both full-depth repaired areas and surrounding areas. This implies that the current requirements for the subbase preparation for the full-depth repair are not adequate. Another cause of longitudinal cracking was due to the use of high CTE aggregate in concrete. Large volume changes in concrete when coarse aggregate with high CTE is used could cause excessive stresses in concrete and result in longitudinal cracking. To prevent longitudinal cracking, attention should be exercised to the selection of concrete materials (concrete with low CTE) and the quality of the construction (timely and sufficient saw cutting and proper selection and compaction of subbase material).     

Stress Corrosion Cracking Behavior of Multipass TIG-Welded AA2219 Aluminum Alloy in 3.5?wt?pct NaCl Solution

The stress corrosion cracking (SCC) behavior of the AA2219 aluminum alloy in the single-pass (SP) and multipass (MP) welded conditions was examined and compared with that of the base metal (BM) in 3.5?wt?pct NaCl solution using a slow-strain-rate technique (SSRT). The reduction in ductility was used as a parameter to evaluate the SCC susceptibility of both the BM and welded joints. The results showed that the ductility ratio (?? _NaCl/(?? _air) was 0.97 and 0.96, respectively, for the BM and MP welded joint, and the same was marginally reduced to 0.9 for the SP welded joint. The fractographic examination of the failed samples revealed a typical ductile cracking morphology for all the base and welded joints, indicating the good environmental cracking resistance of this alloy under all welded conditions. To understand the decrease in the ductility of the SP welded joint, preexposure SSRT followed by microstructural observations were made, which showed that the decrease in ductility ratio of the SP welded joint was caused by the electrochemical pitting that assisted the nucleation of cracks in the form of corrosion induced mechanical cracking rather than true SCC failure of the alloy. The microstructural examination and polarization tests demonstrated a clear grain boundary (GB) sensitization of the PMZ, resulting in severe galvanic corrosion of the SP weld joint, which initiated the necessary conditions for the localized corrosion and cracking along the PMZ. The absence of PMZ and a refined fusion zone (FZ) structure because of the lesser heat input and postweld heating effect improved the galvanic corrosion resistance of the MP welded joint greatly, and thus, failure occurred along the FZ.     

Improved Longitudinal Joint Details in Decked Bulb Tees for Accelerated Bridge Construction: Fatigue Evaluation

This companion paper focuses on an investigation of improved continuous longitudinal joint details for decked precast prestressed concrete girder bridge systems. Precast concrete girders with an integral deck, which are cast and prestressed with the girder, provide benefits of rapid construction along with improved structural performance and durability. Despite these advantages, the use of this type of construction has been limited to isolated regions of the United States. One of the issues limiting more widespread use is the perceived problem with durability of longitudinal joints used to connect adjacent girders. Four full-scale slabs connected by No. 16 (#5) headed reinforcement detail using a 152 mm (6 in.) lap length were fabricated and tested. An analytical parametric study was conducted to provide a database of maximum forces in the longitudinal joint. These maximum forces are then used to determine the loading demand necessary in the slab testing due to the service live load. Static and fatigue tests under four-point pure-flexural loading, as well as three-point flexural-shear loading, were conducted. Test results were evaluated based on flexural capacity, curvature behavior, cracking, deflection, and steel strain. Based on these test results, the improved longitudinal joint detail is a viable connection system that transfers the forces between the adjacent decked bulb tee girders.     

PCC Airfield Pavement Response during Thaw-Weakening Periods

A field study was performed at two regional airports in Wisconsin during spring thaw to determine its effects on portland cement concrete (PCC) airport pavements. This study was part of a research program to model the performance of airfield pavements for the Federal Aviation Administration. Subsurface temperature and falling weight deflection measurements of the pavement structures were taken at both airports and used to calculate the frost penetration depths, the changes in bearing capacity, and the joint and load transfer efficiencies. This paper summarizes the findings of this study and includes several relationships between various engineering properties of the subsurface layers below the PCC layer, along with a procedure for evaluating pavement performance using falling weight deflection data for PCC pavements during spring thaw.     

Inspecting the Lightweight Precast Concrete Panels in the Woodrow Wilson Bridge Deck of 1982

This paper presents the results of a detailed inspection of the deck panels of the Woodrow Wilson Bridge installed in 1982. The original cast-in-place concrete deck, constructed in 1962, was replaced with full-depth lightweight precast concrete deck panels that enabled rapid construction with minimal traffic disruption. The inspection of the Woodrow Wilson deck provides valuable information about the performance of the precast concrete panels, joints, and connections after 20 years of very harsh traffic loads and environmental stressors. The deck panels performed well overall, with the only serious problems at expansion and contraction joints. All of these joints exhibited cracking and rusting. The most prevalent type of cracking appeared to be due to restrained shrinkage between the new polymer concrete, the older precast panels, and the rigid steel joints. This location is more vulnerable to cracking and leaking because there is no prestress across the joint. The multilayered corrosion protection methods used for the transverse and longitudinal post-tensioning tendons were very successful.     

某型机接头裂纹分析

某型机在进行地面检查时,发现有4个同图号接头的螺纹处存在4～10 mm长度不等的磁痕显示.用化学分析、金相检验、扫描电镜、能谱分析等方法对接头裂纹进行了分析.结果表明:故障接头裂纹性质属过载引起的多源疲劳,裂纹产生的时间应在表面处理之前的机加工过程中,且在表面处理后的使用过程中没有进一步扩展.     

Performance of Dowel Bar Retrofit Projects in Texas

In Texas, many miles of plain jointed concrete pavement (JCP) were constructed without proper load transfer devices such as dowels. After a number of years of service, some JCP sections without dowels showed distresses in the form of faulting at transverse joints. Some of the sections were designed in accordance with the AASHTO 1986 Guide, which required 50–75?mm thicker slabs in exchange for not using dowels. This pavement design did not work, with faulting at transverse joints that cause poor ride. Dowel bar retrofit (DBR) was performed on four projects to restore the pavement condition. Overall, DBR restored load transfer efficiency and resulted in improvement of ride quality. Even where the subbase stiffness is 5–10 times less than the minimum value required for proper performance of JCPs, properly installed DBR effectively restored pavement condition with minimum faulting after decades of service. Therefore, it indicated that DBR is able to minimize the faulting even where there is poor base/subgrade support. This is significant in that there are no effective and practical methods to improve subbase conditions in existing concrete pavement, whereas DBR can restore pavement conditions at a reasonable cost. However, not all DBR projects were successful. In one DBR project, faulting in the range of 6.4–9.5?mm occurred after less than 2 years of treatment. Forensic investigation revealed voids under the dowel bars, which indicates poor consolidation of the grout material. Efforts are currently underway in TxDOT to improve specifications for grout materials and DBR construction.     

Construction Management of a Small-Scale Accelerated Pavement Testing Facility

Research in accelerated pavement testing (APT) facilities has traditionally focused on the pavement performance such as rutting and fatigue cracking, but documentation on construction management and information of the actual pavement construction quality is limited. There are typically four critical factors that need to be considered to achieve the best possible outcome in construction: cost, schedule, construction process, and quality control, and management. With the objective of developing guidelines for planning and executing construction of a small-scale APT facility, this paper presents a case study documenting and evaluating the construction process and construction management efforts of two sensor-instrumented hot mix asphalt pavement test sections built in a small-scale APT facility. The focus of the experiment was to study bottom-up fatigue cracking of the flexible pavement structure. The presented information and lessons learned serve as a template and guide for agencies pursuing this type of research and pavement construction.     

Investigation of a Pavement Premature Failure on a Weak and Moisture Susceptible Base

An investigation was conducted to determine the root cause of the premature pavement failure. The premature pavement failure occurred in the form of rutting and alligator cracking. Although the affected portion was repaired by removing and replacing the top 75-mm asphalt concrete (AC), the repaired AC experienced recurring rutting and alligator cracking in a few weeks. Through extensive field and lab testing, it was found that the weak base is the root cause of the premature failure and the brittleness of the AC is secondary. However, both the base and AC were built according to plan and met the current material and field density requirements. It was concluded that density alone for construction quality control is not sufficient, as it was not able to protect against premature failures from occurring. Although there are many different ways to minimize premature failures, an immediate action is to include proof rolling in construction quality control. Proof rolling has been used with success to ensure proper compaction and to locate unstable areas, as the stability is greatly influenced by the degree of densification achieved during compaction.     

Validation of Vibration-Based Onboard Asphalt Density Measuring System

The nuclear density gauge served the industry well for almost forty years as project owners performed quality control on the asphalt paving and compaction process. Recently, however, the responsibility for quality control of these processes has largely been given to the contractor. This shift in responsibility comes at a particularly unfavorable time for the average paving contractor. The construction industry is faced with the worst labor shortage in history, limiting the number of qualified quality control technicians and equipment operators. In addition, this is the dawn of the age of Superpave, a family of hot-mix asphalt mixes designed to combat pavement rutting by increasing the quantity of large aggregate in the mixes. Understandably, these are more difficult to compact. The Onboard Density Measuring System, a model patented by Penn State University, offers density measurements in real time at a rate of one per second during the compaction process, thereby affording the constructor the opportunity to recognize and correct compaction problems immediately while maintaining a permanent record of the entire compaction process.     

Development and Evaluation of an Adhesively Bonded Panel-to-Panel Joint for a FRP Bridge Deck System

A fiber-reinforced polymer (FRP) composite cellular deck system was used to rehabilitate a historical cast iron thru-truss structure (Hawthorne St. Bridge in Covington, Va.). The most important characteristic of this application is reduction in self-weight, which raises the live load-carrying capacity of the bridge by replacing the existing concrete deck with a FRP deck. This bridge is designed to HL-93 load and has a 22.86?m clear span with a roadway width of 6.71?m. The panel-to-panel connections were accomplished using full width, adhesively (structural urethane adhesive) bonded tongue and groove splices with scarfed edges. To ensure proper construction, serviceability, and strength of the splice, a full-scale two-bay section of the bridge with three adhesively bonded panel-to-panel connections was constructed and tested in the Structures Laboratory at Virginia Tech. Test results showed that no crack initiated in the joints under service load and no significant change in stiffness or strength of the joint occurred after 3,000,000 cycles of fatigue loading. The proposed adhesive bonding technique was installed in the bridge in August 2006.     

Effect of Repair Welding on Electrochemical Corrosion and Stress Corrosion Cracking Behavior of TIG Welded AA2219 Aluminum Alloy in 3.5 Wt Pct NaCl Solution

The stress corrosion cracking (SCC) behavior of AA2219 aluminum alloy in the as-welded (AW) and repair-welded (RW) conditions was examined and compared with that of the base metal (BM) in 3.5 wt pct NaCl solution using the slow strain rate technique (SSRT). The reduction in ductility was used as a parameter to evaluate the SCC susceptibility of both BM and welded joints. The results show that the ductility ratio (ε _NaCl/(ε _air)) of the BM was close to one (0.97) and reduced to 0.9 for the AW joint. This value further reduced to 0.77 after carrying out one repair welding operation. However, the RW specimen exhibited higher ductility than the single-weld specimens even in 3.5 wt pct NaCl solution. SSRT results obtained using pre-exposed samples followed by post-test metallographic observations clearly showed localized pitting corrosion along the partially melted zone (PMZ), signifying that the reduction in ductility ratio of both the AW and RW joints was more due to mechanical overload failure, caused by the localized corrosion and a consequent reduction in specimen thickness, than due to SCC. Also, the RW joint exhibited higher ductility than the AW joint both in air and the environment, although SCC index (SI) for the former is lower than that of the latter. Fractographic examination of the failed samples, in general, revealed a typical ductile cracking morphology for all the base and welded joints, indicating the good environmental cracking resistance of this alloy. Microstructural examination and polarization tests further demonstrate grain boundary melting along the PMZ, and that provided the necessary electrochemical condition for the preferential cracking on that zone of the weldment.     

Quality of Runoff Leachate Collected from Biosolids and Dairy-Manure Compost-Amended Topsoils

Compost amendment of pavement shoulder subgrades was attempted to mitigate shrinkage cracking, which otherwise would result in severe distress to adjacent pavement infrastructure systems. Two types of composts, biosolids and dairy-manure composts, were evaluated. As a part of this application, the runoff leachate emanating from the compost soils needs to be environmentally assessed as this leachate potentially ends up in storm sewer collection systems. As a part of the research, runoff collection systems were placed in both dairy-manure and biosolids compost-amended soil sections and a control untreated soil section. The collected water samples at various time intervals were then subjected to various chemical and environmental tests, including total suspended and dissolved solids, biochemical and chemical oxygen demand, total Kjeldahl nitrogen (TKN), and phosphorous measurements. This paper presents a summary of these test results from both sections and their comparisons with similar results from another leachate collected from a control or untreated section. These test results are also compared with a few local studies conducted on highway runoff samples and EPA benchmark values. Possible causes for chemical contaminant concentration differences in the leachate samples from both composts are also explained.     

Mechanical and elemental characterization of solder joints and welds using a gold-palladium alloy

PURPOSE: This study was conducted to determine whether newer infrared or laser welding technologies created joints superior to traditional furnace or torch soldering methods of joining metals. It was designed to assess the mechanical resistance, the characteristics of the fractured surfaces, and the elemental diffusion of joints obtained by four different techniques: (1) preceramic soldering with a propane-oxygen torch, (2) postceramic soldering with a porcelain furnace, (3) preceramic and (4) postceramic soldering with an infrared heat source, and (5) laser welding. MATERIAL AND METHODS: Mechanical resistance was determined by measuring the ultimate tensile strength of the joint and by determining their resistance to fatigue loading. Elemental diffusion to and from the joint was assessed with microprobe tracings. Scanning electron microscopy micrographs of the fractured surface were also obtained and evaluated. RESULTS: Under monotonic tensile stress, three groups emerged: The laser welds were the strongest, the preceramic joints ranged second, and the postceramic joints were the weakest. Under fatigue stress, the order was as follows: first, the preceramic joints, and second, a group that comprised both postceramic joints and the laser welds. Inspection of the fractographs revealed several fracture modes but no consistent pattern emerged. Microprobe analyses demonstrated minor diffusion processes in the preceramic joints, whereas significant diffusion was observed in the postceramic joints. CLINICAL IMPLICATIONS: The mechanical resistance data conflicted as to the strength that could be expected of laser welded joints. On the basis of fatigue resistance of the joints, neither infrared solder joints nor laser welds were stronger than torch or furnace soldered joints.