History of Concrete Paving In Iowa - Iowa State University Extension ...
History of Concrete Paving In Iowa - Iowa State University Extension ...
History of Concrete Paving In Iowa - Iowa State University Extension ...
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Todd Hanson, PE<br />
<strong>Concrete</strong> Materials Engineer, <strong>Iowa</strong> DOT<br />
Better <strong>Concrete</strong> Conference, November 7, 2013
<strong>In</strong>tro<br />
• <strong>Iowa</strong> has a rich history<br />
<strong>of</strong> concrete paving<br />
• Explore how we got<br />
here<br />
• Changes in the last<br />
100 years
<strong>Concrete</strong> Pavement-Gets<br />
<strong>Iowa</strong> Out <strong>of</strong> the Mud<br />
• <strong>In</strong>terest <strong>of</strong> public<br />
mud, dust, deep sand<br />
• Natural resources<br />
▫ Northwestern 1908<br />
▫ Hawkeye 1910<br />
▫ Lehigh 1911<br />
▫ Dewey 1927<br />
• Royalty fee for<br />
asphalt
1904 1st <strong>Concrete</strong> Pavement in <strong>Iowa</strong><br />
• First Street (Eagle<br />
St) in Lemars <strong>Iowa</strong><br />
• 2 nd oldest concrete<br />
street in America<br />
• Two businessman<br />
fed up with dust<br />
when dry & mud<br />
when wet
1904 1st <strong>Concrete</strong> Pavement in <strong>Iowa</strong><br />
• Two lift construction similar to<br />
sidewalk construction at the<br />
time (½” surface )<br />
• 5” lean base, 1 ½” surface with<br />
significantly higher cement<br />
content<br />
• 6ft diagonal panels scored 4<br />
inch squares to prevent horse<br />
slipping
1909 - Eddyville Cemetery Rd<br />
• Oldest Farm to<br />
Market Road in <strong>Iowa</strong><br />
• Top 10 oldest in<br />
America<br />
• Citizens fed up with<br />
deep sand during dry<br />
weather
1913 -<strong>Iowa</strong> Highway Commission<br />
Several Short Projects Built<br />
• Cerro Gordo<br />
• Louisa<br />
• Benton<br />
• Dallas<br />
• Muscatine (1914)<br />
Moscow Road – 2011 ( 16 ft. wide, 25 ft joints)
1917 - <strong>Iowa</strong> FA-1 Cerro Gordo Co.<br />
Specifications<br />
• Type A (FD) or Type B (two<br />
coarse)<br />
• 1 st penalty clause<br />
▫ Divide into 50 ft blocks<br />
▫ Count bags <strong>of</strong> cement<br />
▫ If any 3 adjacent blocks 4%<br />
less or 7 1/2 % more,<br />
remove and replace the<br />
blocks<br />
• Surface struck with template or<br />
strike board - No limitations<br />
• Texture 3 -ply belt 10” wide<br />
• Curing 1 day wet burlap/10<br />
days wet earth<br />
Federal Aid Project No. 1 -1917<br />
6” thick, 16ft wide w/ ½” square<br />
transverse bars every 15’ 1”
1918 – Seedling Mile<br />
• Linn County<br />
• Northwestern <strong>State</strong>s Cement<br />
donated 3,000 barrels <strong>of</strong><br />
cement<br />
• Ford <strong>Paving</strong> Company bid <strong>of</strong><br />
$3.15/yd 2<br />
• Highway Comission talked them<br />
down to $2.84/yd 2<br />
▫ Changed to Muscatine Gravel<br />
▫ Changed from Type B (two<br />
course) to Type A (single<br />
course)
Mixing -Early Steam Mixers<br />
• Not self propelled<br />
• Mix by Volume 1:2:3<br />
▫ 1.7 bbls / yd3<br />
• 94 lb bag = 1ft3<br />
• Aggregates -<br />
proportioned by<br />
bottomless 1 ft3 box<br />
in wheelbarrow<br />
▫ Marked a line<br />
• Bulking effect<br />
• Counted shovels<br />
when less inspection<br />
• Water by sound
Preparation <strong>of</strong> Subgrade<br />
• 1920’s<br />
• Sprinkle with water<br />
uniformly moist or<br />
cover with tar paper<br />
• Plastic 1960
1921 - Woodbury US 20<br />
• By 1921, development <strong>of</strong><br />
tools & equipment to<br />
reduce back breaking<br />
labor<br />
• Cranes with clam shells<br />
buckets unloaded<br />
aggregates from rail cars<br />
into bins<br />
• Dumped into single batch<br />
trucks
Materials Delivered by Truck<br />
• Dry materials dumped into<br />
skip hoist
Cement Bags Dumped on Aggregate in Skip
Other Method - <strong>In</strong>dustrial Rail Cars
Mixer<br />
• Self propelled<br />
• Water lines laid out<br />
along grade<br />
• <strong>Concrete</strong> deposited by<br />
swinging boom &<br />
bucket
Finishing Machine<br />
• Operated on steel forms<br />
• Machines had tamping bar &<br />
two opposed adjustable<br />
oscillating transverse<br />
screeds<br />
• Most popular brands –<br />
Lakewood and Ord
Longitudinal Finishing<br />
• 12 foot by 12<br />
inch wide by 3<br />
inch thick<br />
wood float<br />
• Combined<br />
longitudinal<br />
and transverse<br />
motion across<br />
surface
Belting Surface<br />
• Use combined<br />
transverse and<br />
longitudinal motion<br />
with a minimum 8<br />
inch wide belt<br />
across the surface<br />
to remove tool<br />
marks and produce<br />
a gritty texture
Curing 1 day Wet Burlap
7 day -2” <strong>of</strong> Wet Earth Cure
Old US 20 -2009<br />
Old US 20 – 8 “ Thick- 16 ft wide No joints
Alternate<br />
Curing<br />
Methods<br />
Curecrete<br />
Ponding
Longitudinal Joint<br />
• Prior to 1920 transverse joints<br />
12 to 35 ft intervals<br />
• 1920 to 1925 – No transverse<br />
or longitutinal joints<br />
• 1925 to 1929 – Steel or mastic<br />
longitudinal joint, No transverse
Expansion Joints<br />
• 1930 & later – transverse<br />
expansion joints 80 to 100 ft<br />
intervals
1924 - US 20 Woodbury<br />
Batching <strong>Concrete</strong> by Weight
1925 - Mixing by Weight<br />
• Variable concrete produced<br />
due to sand bulking - moisture<br />
variations<br />
• Roy W. Crum, Materials & Tests<br />
Engineer considerable work on<br />
concrete proportioning<br />
• 1924 research proved weight<br />
was more reliable method<br />
• 1925, Highway Commission<br />
specified weight measurement<br />
• Became the universal standard<br />
method worldwide
1925 Gas / Diesel Mixers<br />
• Steam mixers<br />
retired<br />
• Powered by gas or<br />
diesel fuel
Bulk Cement in<br />
Rail Car<br />
• Bulk cement became<br />
available in the early<br />
1930’s<br />
• Cement batching<br />
plants eliminated<br />
the use <strong>of</strong> bags<br />
Bulk cement – Howard Co. 1931
1933 - Smoothness<br />
• 1921 to 1933<br />
▫ 1/4” in 10 ft.<br />
• 1933 to 1976<br />
▫ 1/8” in 10 ft.<br />
• Correction with<br />
carborundum brick
1937 - Vibration<br />
• Operated at no less than 3,500<br />
vpm’s
1952 – <strong>Concrete</strong><br />
Air Entrained <strong>Concrete</strong><br />
• 1952 3-5%<br />
• 1956 4-6%<br />
• 1960 6±1%<br />
Mix Design<br />
• Absolute volumes similar to<br />
Class C mixes
Early 1950’s – Center Parting Strip<br />
• Continuous inserted parting strip<br />
• Tended to wander<br />
• Air entrained concrete stickier<br />
• Longitudinal finishing removed<br />
from required equipment
1956<br />
• Sawing <strong>of</strong> transverse<br />
longitudinal joint<br />
required
Development <strong>of</strong><br />
Slip Form Paver<br />
• 1947 – James Johnson & Bert<br />
Myers Office <strong>of</strong> Materials<br />
conceptualized extrusion<br />
process<br />
▫ 18” wide / 3” thick sidewalk<br />
• 1948 - Improved prototype<br />
produced 4’ wide 5” thick<br />
sidewalk<br />
• 1949 – Full scale prototype<br />
placed 1 st slip form pavement in<br />
Obrien & Cerro Gordo county<br />
▫ Two 10ft passes<br />
▫ 3-4” gap filled with AC
Development <strong>of</strong> Slip<br />
Form Paver<br />
• Little advancement until 1954<br />
• Greene county wanted to try<br />
slip form<br />
• Leased to Ray Andrews<br />
• Andrews removed the hopper<br />
and deposited concrete on the<br />
grade in front <strong>of</strong> the paver as is<br />
done today<br />
• Gap was filled with concrete
1955 - 1 st Commercial Slip form paver<br />
• Quad City slip<br />
form paver<br />
• Soon other<br />
manufacturers<br />
followed<br />
• Became the<br />
standard method<br />
<strong>of</strong> placement
Ist Slip form on <strong>In</strong>terstate I80 <strong>Iowa</strong> Co 1964<br />
• <strong>In</strong> <strong>Iowa</strong>, slip form paving on interstate and primary paving would not<br />
become as predominant as it is today until the late 1970’s and early 80’s<br />
• Central batch mixing also used on this project and became more<br />
predominant during construction <strong>of</strong> the interstate<br />
• 27E, 31E & 34 E batch mixers retired
Pavement Design<br />
• Uniform depth until 1926<br />
• Thickened edge design 1926-<br />
1957<br />
• 18ft wide until mid-1930’s<br />
• 20ft wide until 1948<br />
• 22 ft wide until 1959<br />
• Steel – alternating sides across<br />
longitudinal joint<br />
• Expansion joint with load<br />
transfer every 80 to 120 ft
1950’s - Pavement Widening<br />
• Narrow widths placed<br />
• Upgrading to modern<br />
standards<br />
• Numerous curb removal<br />
widening projects during<br />
the 1950’s
Load Transfer<br />
• 1958 to 1969 – 20 foot joint<br />
spacing with aggregate interlock<br />
• Load transfer<br />
▫ ADTT >500 -1969<br />
▫ ADTT>300 -1995<br />
• Joints perpendicular until 1980<br />
• Skewed 6:1 1981 to 2004<br />
• Perpendicular 2005<br />
• ATB or CTB subbase specified<br />
ADTT>700 1976 to 1981<br />
• Granular subbase 1989<br />
• ADTT>300 1995
1958 – <strong>In</strong>terstate <strong>Paving</strong><br />
• 1958 to 1966 jointed<br />
reinforced<br />
• 76.5’ joint spacing<br />
• Mesh reinforced<br />
• Tandem pavers<br />
▫ Bottom lift placed<br />
▫ Place mesh<br />
• Top layer placed by<br />
second paver
<strong>In</strong>terstate CRC <strong>Paving</strong><br />
• 1966 - Early CRC was placed on<br />
chairs<br />
• 8 inch thick on<br />
▫ Granular subase 1966-1967<br />
▫ ATB or CTB 1968-1976
<strong>In</strong>terstate CRC paving<br />
• <strong>Iowa</strong> First - 1967<br />
• Steel fed through machine – No<br />
transverse steel<br />
• Bottom layer placed<br />
• Steel placed on top<br />
• Second paver pass<br />
• Problems because steel not<br />
placed at central axis.
1960’s -<strong>Iowa</strong> Special<br />
Trimmer/Placer<br />
• Allowed full width placement<br />
on county roads with minimal<br />
working area<br />
• Conveyer attached to trimmer<br />
• Trucks placed material on<br />
conveyer<br />
• <strong>Concrete</strong> deposited over the top<br />
on the trimmed subgrade
1971 – Aggregate<br />
Durability Classification<br />
• 1920’s Pit run gravels used<br />
• Coarse & fine aggregate<br />
• 1930’s few limestone sources<br />
▫ Alden - good<br />
▫ Glory – bad<br />
• 1950’s more sources – interstate<br />
▫ Bethany Falls / Argentine<br />
• 1971 Class 2 – <strong>Paving</strong>, Class 1<br />
Structures<br />
• 1982 Class 3 <strong>Paving</strong>, Class 2 other<br />
pavements<br />
• 1992 Class 3I – 40 year design life<br />
• Unique system today - <strong>Iowa</strong> Pore index<br />
test & chemical testing <strong>of</strong> aggregates
<strong>Concrete</strong> Overlays<br />
• <strong>Concrete</strong> overlays are not new<br />
in <strong>Iowa</strong><br />
• Several overlays (resurfacing)<br />
projects were placed in the<br />
1930’s to 1950’s<br />
• 1960 Woodbury County over<br />
asphalt<br />
▫ Gravel interlayer<br />
• 1971 Storm Lake Airport on<br />
asphalt<br />
US 30 Benton Co 1949 - 6 inch PCC resurfacing
Modern<br />
<strong>Concrete</strong> Overlays<br />
• 1973 Greene County<br />
• Bonded and un-bonded sections<br />
placed<br />
• Steel fibers<br />
• CRC & mesh Reinforced<br />
• 1976 – Woodbury & Blackhawk<br />
thin bonded overlays<br />
• 1977 – Boone, Dallas,<br />
Washington counties placed<br />
whitetopping overlays<br />
• <strong>Iowa</strong> county road system has<br />
placed as many miles <strong>of</strong><br />
concrete overlays as the total in<br />
the USA
1976 - Tining<br />
• Guidelines for Skid-Resistant<br />
Pavement Design published by<br />
AASHTO in 1976 to provide safe<br />
wet weather friction<br />
• Accomplished by turf or burlap<br />
drag and ¾” spaced transverse<br />
tining<br />
• 1999 changed to longitudinal<br />
tining – improved noise<br />
characteristics
1977 – Recycled<br />
Aggregates<br />
• Existing pavement recycled as<br />
coarse aggregate<br />
• US 75 Lyon, IA 2 Taylor, I-680<br />
Pott.<br />
• Class 2 or better Aggregate<br />
sources<br />
▫ 1979 - 191 sources<br />
▫ 2012 - 298 sources
Water Reducers<br />
& Fly ash<br />
• 1974 Water reduced mix<br />
designs C-3WR & C-4WR<br />
• 1978 -1 st use <strong>of</strong> fly ash<br />
Woodbury & Monona Co.<br />
• 1984 – Contractors Option<br />
▫ 15 to 20%<br />
Woodbury County - 1978
Smoothness<br />
• 1977 Correction <strong>of</strong> high spot by<br />
diamond grinding<br />
• 1981 -1 st use <strong>of</strong> the California<br />
type, 25 foot pr<strong>of</strong>ilograph<br />
• 100%
Maturity Method to<br />
Determine Opening<br />
• Prior to utilizing maturity<br />
method – opening strength<br />
determined by beam break and<br />
5 to 7 days<br />
• 1995 Research in Lee County<br />
• 1997 -Contractor’s option to<br />
use maturity method <strong>of</strong> opening<br />
• <strong>Iowa</strong> one <strong>of</strong> the first states to<br />
implement the method for<br />
opening
Slag and<br />
Blended Cements<br />
• First use <strong>of</strong> slag in project 1995<br />
▫ Linn Co IA 100<br />
• Type IS cements with fly ash<br />
• Type IP cement 1995<br />
▫ I-29 Pottawattamie Co<br />
• Type IP cements with fly ash<br />
• <strong>Iowa</strong> most miles <strong>of</strong> ternary<br />
mixes in the country<br />
▫ 600 miles slag & fly ash<br />
▫ 225 miles IP & fly ash
Stringless <strong>Paving</strong><br />
• Washington county research<br />
2003<br />
• Developmental Specification<br />
2011
Conclusions<br />
• <strong>Iowa</strong> has been a leader in a number <strong>of</strong> concrete paving<br />
achievements<br />
▫ Batching by weight<br />
▫ Slip form paver<br />
▫ Overlays<br />
▫ Maturity Method<br />
▫ Ternary mixes<br />
• Many changes occurred in the last 100 years<br />
• Learned from mistakes and capitalized on successes<br />
• Partnership with industry has been a key to success
Structures – <strong>Iowa</strong> Firsts<br />
Questions<br />
1893 – Lyon County - First reinforced<br />
concrete bridge in the United <strong>State</strong>s<br />
1963 – <strong>Iowa</strong> Method <strong>of</strong> Low Slump,<br />
dense <strong>Concrete</strong> Bridge Deck Overlay
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