Material and Construction Optimization for Prevention of Premature Pavement Distress in PCC Pavements: Final Report Final Report March 2008 Sponsored through Federal Highway Administration Pooled Fund Study TPF-5(066) and the Iowa Department of Transportation (Lead State) Iowa State University’s Center for Transportation Research and Education is the umbrella organization for the following centers and programs: Bridge Engineering Center • Center for Weather Impacts on Mobility and Safety • Construction Management & Technology • Iowa Local Technical Assistance Program • Iowa Traffi c Safety Data Service • Midwest Transportation Consortium • National Concrete Pavement Technology Center • Partnership for Geotechnical Advancement • Roadway Infrastructure Management and Operations Systems • Statewide Urban Design and Specifications • Traffic Safety and Operations About the National Concrete Pavement Technology Center The mission of the National Concrete Pavement Technology Center is to unite key transportation stakeholders around the central goal of advancing concrete pavement technology through research, tech transfer, and technology implementation. Disclaimer Notice The contents of this report reflect the views of the authors, who are responsible for the facts and the accuracy of the information presented herein. The opinions, findings and conclusions expressed in this publication are those of the authors and not necessarily those of the sponsors. The sponsors assume no liability for the contents or use of the information contained in this document. This report does not constitute a standard, specification, or regulation. The sponsors do not endorse products or manufacturers. Trademarks or manufacturers’ names appear in this report only because they are considered essential to the objective of the document. Non-discrimination Statement Iowa State University does not discriminate on the basis of race, color, age, religion, national origin, sexual orientation, gender identity, sex, marital status, disability, or status as a U.S. veteran. Inquiries can be directed to the Director of Equal Opportunity and Diversity, (515) 294-7612. Technical Report Documentation Page 1. Report No. 2. Government Accession No. 3. Recipient’s Catalog No. Pooled Fund Study TPF-5(066) 4. Title and Subtitle 5. Report Date Material and Construction Optimization for Prevention of Premature Pavement March 2008 Distress in PCC Pavements: Final Report 6. Performing Organization Code 7. Author(s) 8. Performing Organization Report No. Jim Grove, Gary Fick, Tyson Rupnow, and Fatih Bektas 9. Performing Organization Name and Address 10. Work Unit No. (TRAIS) National Concrete Pavement Technology Center Iowa State University 11. Contract or Grant No. 2711 South Loop Drive, Suite 4700 Ames, IA 50010-8664 12. Sponsoring Organization Name and Address 13. Type of Report and Period Covered Federal Highway Administration Final Report U.S. Department of Transportation 14. Sponsoring Agency Code 400 7th Street SW, HIPT-20 Washington, DC 20590 15. Supplementary Notes Visit www.cptechcenter.org for color PDF files of this and other research reports. 16. Abstract Mixture materials, mix design, and pavement construction are not isolated steps in the concrete paving process. Each affects the other in ways that determine overall pavement quality and long-term performance. However, equipment and procedures commonly used to test concrete materials and concrete pavements have not changed in decades, leaving gaps in our ability to understand and control the factors that determine concrete durability. The concrete paving community needs tests that will adequately characterize the materials, predict interactions, and monitor the properties of the concrete. The overall objectives of this study are (1) to evaluate conventional and new methods for testing concrete and concrete materials to prevent material and construction problems that could lead to premature concrete pavement distress and (2) to examine and refine a suite of tests that can accurately evaluate concrete pavement properties. The project included three phases. In Phase I, the research team contacted each of 16 participating states to gather information about concrete and concrete material tests. A preliminary suite of tests to ensure long-term pavement performance was developed. The tests were selected to provide useful and easy-to-interpret results that can be performed reasonably and routinely in terms of time, expertise, training, and cost. The tests examine concrete pavement properties in five focal areas critical to the long life and durability of concrete pavements: (1) workability, (2) strength development, (3) air system, (4) permeability, and (5) shrinkage. The tests were relevant at three stages in the concrete paving process: mix design, preconstruction verification, and construction quality control. In Phase II, the research team conducted field testing in each participating state to evaluate the preliminary suite of tests and demonstrate the testing technologies and procedures using local materials. A Mobile Concrete Research Lab was designed and equipped to facilitate the demonstrations. This report documents the results of the 16 state projects. Phase III refined and finalized lab and field tests based on state project test data. The results of the overall project are detailed herein. The final suite of tests is detailed in the accompanying testing guide. 17. Key Words 18. Distribution Statement concrete materials—construction practices—field testing—quality control No restrictions. 19. Security Classification (of this 20. Security Classification (of this 21. No. of Pages 22. Price report) page) Unclassified. Unclassified. 296 NA Form DOT F 1700.7 (8-72) Reproduction of completed page authorized MATERIAL AND CONSTRUCTION OPTIMIZATION FOR PREVENTION OF PREMATURE PAVEMENT DISTRESS IN PCC PAVEMENTS Final Report March 2008 Principal Investigator Jim Grove PCC Paving Engineer National Concrete Pavement Technology Center, Iowa State University Co-Principal Investigators Gary Fick Trinity Construction Management Services Bob Steffes National Concrete Pavement Technology Center, Iowa State University Research Assistants Fatih Bektas Tyson Rupnow Research Technicians Heath Gieselman Jeremy McIntyre Bryan Zimmerman Sponsored through Federal Highway Administration Pooled Fund Study TPF-5(066) and the Iowa Department of Transportation (Lead State) A report from National Concrete Pavement Technology Center Iowa State University 2711 South Loop Drive, Suite 4700 Ames, IA 50010-8664 Phone: 515-294-8103 Fax: 515-294-0467 www.cptechcenter.org TABLE OF CONTENTS ACKNOWLEDGMENTS ............................................................................................................ XI INTRODUCTION ...........................................................................................................................1 Problem Statement...............................................................................................................1 Project Background..............................................................................................................1 Project Objectives ................................................................................................................1 Overview of Project Phases .................................................................................................2 Pooled Fund Partnership......................................................................................................2 Project Organization ............................................................................................................4 PHASE I. EXISTING STATE KNOWLEDGE AND PRELIMINARY SUITE OF TESTS .........6 Phase I Overview .................................................................................................................6 Research Focus and Framework ..........................................................................................6 Data Collection ....................................................................................................................7 Visits to Participating States................................................................................................8 Coordinated Research ..........................................................................................................9 Phase I Key Findings .........................................................................................................10 Preliminary Suite of Tests..................................................................................................14 PHASE II AND III. FIELD DEMONSTRATIONS AND REFINED SUITE OF TESTS...........15 Phase II and III Overview..................................................................................................15 Suite of Tests .....................................................................................................................16 MCO Mobile Concrete Research Lab ...............................................................................20 Air Void Analyzer .............................................................................................................24 Other Tests Identified During the State Visits...................................................................29 Unusual Occurrences during the State Visits ....................................................................31 Phase II and III Key Findings ............................................................................................35