As of 2005, 23% of the bridges in the Kansas infrastructure are classified as structurally deficient or functionally obsolete according to the ASCE Infrastructure Report Card (ASCE, 2008). One alternative to replacing the entire bridge structure is replacing only the superstructure with lightweight concrete. This option is more economical for city, county, and state governments alike. Replacing the superstructure with lightweight concrete can oftentimes allow the bridge rating to be upgraded to higher load capacities or higher traffic volumes. Furthermore, lightweight concrete can be used initially in a bridge deck to provide reduced weight and a lower modulus of elasticity, therefore lower cracking potential. The Kansas Department of Transportation is interested in the potential benefits of using lightweight aggregate concrete in Kansas bridge decks and prestressed bridge girders. This research project used three types of lightweight aggregate to develop lightweight concrete mixtures for a bridge deck and for prestressed bridge girders. Two of the lightweight aggregates were expanded shale obtained locally from the Buildex Company. One deposit was located in Marquette, Kansas, and the other in New Market, Missouri. The third lightweight aggregate source was expanded slate obtained from the Stalite Company in North Carolina. Aggregate properties including absorption, gradation, and L.A. Abrasion were evaluated. Over 150 lightweight concrete mixtures were created and tested and several mix design variables such as water-to-cement ratio, cement content, and coarse-to-fine aggregate ratio were evaluated. From these results, optimized bridge deck and optimized prestressed concrete mixtures were developed for each type of lightweight aggregate. Special concerns for lightweight aggregate concrete are addressed. These optimized concrete mixtures were then tested for KDOT acceptability standards for the concrete properties of compressive strength, tensile strength, modulus of elasticity, freeze-thaw resistance, permeability, alkali-silica reactivity, drying shrinkage, and autogenous shrinkage. All concrete mixtures performed satisfactorily according to KDOT standards. In addition, an internal curing effect due to the moisture content of the lightweight aggregate was observed during the autogenous shrinkage test.

TRB's National Cooperative Highway Research Program (NCHRP) Synthesis 338: Thin and Ultra-Thin Whitetopping summarizes available information to document how state departments of transportation and others are currently using thin and ultra-thin whitetopping overlays among various pavement rehabilitation alternatives. The report covers all stages of the proper application of whitetopping overlays, including project selection, design, materials selection, construction, maintenance, and eventual rehabilitation or replacement.

This study evaluated the impacts of construction on the air content and air-void system structure of Portland cement concrete pavements. The primary intent was to quantify the air content of fresh concrete before and after it has gone through the slipform paver. The air-void system parameters of hardened concrete were then assessed using cast and extracted core specimens. The results of the air content testing on fresh concrete and the concrete cylinder specimens cast in the field suggested that there is some loss of air as the concrete passes through the paver. Laboratory testing performed on cores extracted from the pavement did not provide any conclusive evidence that entrained air is lost during the slipform paving process. In fact, many of the extracted cores had measured air content values that were much higher than the specification requirement. If excessive, this could result in increased permeability and low-strength related issues. Although a rigorous statistical analysis was not performed, the results suggest that the air content testing on fresh concrete is not capturing the true air content of the concrete placed with a slipform paver. The fresh concrete air content is generally lower than the air content measured in the cores.

This report contains guidelines and recommendations for managing and designing for friction on highway pavements. The contents of this report will be of interest to highway materials, construction, pavement management, safety, design, and research engineers, as well as others concerned with the friction and related surface characteristics of highway pavements.