“winter seals” workshop the suppliers · pdf fileroad overnight bitumen rubber...
TRANSCRIPT
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4
“Winter Sealing”
Pretoria10 April 2014
Johan MullerIn conjunction with Kobus Louw
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OVERVIEW
• Supply & Demand
• Impact on Availability of Products
• Impact on Availability of Services
• Seasonal Indexes
• Winter Seal Product Characteristics
• Health Safety & Environment
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HISTORICAL SUPPLY (PROJECTED)
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THEORETICAL SUPPLY & DEMAND
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SUPPLY & DEMAND
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IMPACT ON AVAILABILITY OF PRODUCT
• Bitumen supply shortfalls
• Imported Bitumen
– Price
– Logistics
• Secondary product availability
• Anything is possible but not always practical
• Careful planning required.
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SEASONALITY
• Why is there a seasonality?
• Seasons (Autumn & Winter & Spring)
• RSA Summer Holiday Break
• Budget / Spending Cycle
• Embargo Periods
• Lack of planning (common sense)
• Knowledge base
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WEATHER LIMITATIONSGRADE TEMPERATURE
ROAD OVERNIGHT
Bitumen rubber 25°C ? °C
Bitumen rubber (Winter Grade) As spec by project spec
SBS SBR (ex 80/100) 25°C ? °C
80/100 25°C ? °C
SBS or SBR (ex 150/200) 21°C ? °C
SBS or SBR (Winter Grade) As spec by project spec
150/200 21°C ? °C
MC3000 10°C ? °C
MC800 10°C ? °C
Bitumen Emulsions 10°C ? °C
Modified Bitumen Emulsion 10°C ? °C
Guidelines COLTO 4300-8
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• Supply & Demand for Sprayers
• Cost of fleet
• Staff complement employment
• Hardware Utilization
• Human Capacity Utilization
• Maintenance
• COF’s (Roadworthiness)
• Calibration & Certification (Koedoespoort)
IMPACT ON AVAILABILITY OF SERVICES
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• Supply & Demand for Sprayers
• Cost of fleet
• Staff complement employment
• Hardware Utilization
• Human Capacity Utilization
• Maintenance
• COF’s
IMPACT ON AVAILABILITY OF SERVICES
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Options?
• Go to a softer grade
– 80/100 → 150/200 → MC3000
• Cut back with various cutters (Permitted?)
• Guidelines COLTO 4300-1
• Guidelines TRH3 p52 and APPENDIX I p 209
• Use cold applied products EMULSIONS
WHAT IF TEMPERATURES ARE BELOW?
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Hot-applied binders(penetration grade bitumen)
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Typical cold weather stripping
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Note how little binder is attached tothe aggregate
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Guidelines COLTO 4300-8
Grade ROAD
TEMPERATURE
AIR
TEMPERATURE
OVERNIGHT
TEMPERATURE
80/100 25°C ? ?
150/200 21°C ? ?
MC3000 10°C ? ?
MC800 10°C ? ?
GO TO SOFTER GRADE
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• Why do we cut back?
– Temporary reduction of viscosity
– Ensure wetting
– Volatile cutters evaporate
– Residual binders revert to original seal grades
– Promote early mosaic formation during compaction (re-orientation) allowing road stone embedment
CONSIDER CUT BACK OPTION
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BASED ON NATREF 80/100 TRH3 p52 and APPENDIX I p 209
OVERNIGHT
TEMP
ROAD
TEMP
APPROXIMATE
AIR TEMP
% CUTTER SPRAY
TEMP
>12 > 48 >31 0 150 – 175
9 – 12 40 – 48 26 – 31 2 – 1 132 – 149
6 – 9 32 – 40 21 – 26 4 – 3 121 – 138
3 – 6 24 – 32 16 – 21 7 – 5 115 – 135
0 – 3 16 – 24 10 – 16 9 – 7 100 – 118
< 0 NO SEAL WORK RECOMMENDED
Engineers’ call
CUT BACK GUIDELINE FOR BITUMEN
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Determination of the quantity of cutter (fluxant) required
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Effect of fluxant on bitumen properties on 70/100 pen bitumen
Property
% Paraffin (volume/mass) Specification
Penetration (0,1 mm) 70 110 145 185 251 70 – 100
Softening Point (°C) 48,8 45,1 42,9 40,1 38,6 42 - 51
Visc @ 60 °C (Pa.s) 153 115 72 51 32 > 75
Visc @ 135 °C (Pa.s)0.31 0.24 0.21 0.17 0.15 0,15 – 0,40
Minimum road surface temperature require to retain aggregate (°C)
25 23 21 19 18 -
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70/100 pen bitumen @ 20 °C
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70/100 pen bitumen @ 27 °C
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The effect of fluxing on the
adhesion properties of bitumen
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70/100 pen bitumen (unfluxed)
20 °C
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70/100 pen bitumen + 3% paraffin
20 °C
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70/100 pen bitumen + 5% paraffin
20 °C
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Hot-applied Modified Binders(PMB’s & Bitumen Rubber)
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Fluxing of S-E2Viscosity vs. Temperature
0
200
400
600
800
1000
1200
140 150 160 170 180 190
Vis
cosi
ty (
mP
a.s)
Temp (°C)
70/100
0% flux
2% flux
3% flux
4% flux
5% flux
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Effect of fluxant on properties of S-E2 polymer modified binder
Property
% Paraffin (volume/mass) Recommendation(TG 1)
0 2 3 4 5
Penetration (0,1 mm) 65 99 124 145 190 No spec
Softening Point (°C) 63 54 53 52 51 60 – 80
Viscosity @ 165 °C (Pa.s) 401 331 292 270 227 0,60 max.
Elastic Recovery @ 15 °C (%)81 83 85 83 80 > 70
Minimum road surface temperature require to retain aggregate (°C)
25 23 21 20 18 -
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?
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Comparison 70/100 vs S-E2(fluxed properties)
Property% Cutter
Penetration (0,1 mm)
70/100S-E2
7065
11099
145124
185145
251190
Softening Point (°C)
70/100S-E2
48,863,0
45,154,0
42,953,0
40,152,0
38,651,0
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Conventional Bitumen RubberCriteria more user friendly bitumen rubber product:• Reduce temperature required to manufacture and apply
– from ~ 200°C to < 180°C
• Reduce viscosity to accommodate reduction in temperature• Maintain or improve toughness levels of the product• Maintain or improve elastic response of the product• Improve / increase the shelf-life of the product• Reduce sensitivity to time and the ever-changing physical
properties of the product• Reduce asphalt mixing or spray application temperatures• Reduce sensitivity to temperature • Remove requirement of compaction at high temperatures
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Typical cutter properties
Solvent Paraffin Medium flash point solvent
High flash point solvent
Properties
Flash Point (°C), min 38 62 89
IBP (°C), min 150 180 217
Dry Point (°C), min 252 288 241
Aromatics (%m/m) 18 17 19
Cutter selection will vary depending on the suppliers’ proprietary technology
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PROPERTIES OF BITUMEN-RUBBER CUT BACK WITH VARYING QUANTITIES OF HIGH BOILING POINT SOLVENT
PROPERTY% HYDROCARBON CUTTER
S-R1 SPEC
R & B Softening Point (°C) 61,3 49,1 44,7 41,2 41,0 55 – 62
Resilience (%) 42 3 - - - 13 – 35
Flow @ 60 °C (mm) 20 105 127 134 147 15 – 70
Dynamic viscosity @ 190 °C (dPa.s)
34 26 19 14 9 20 - 40
Minimum recommended road surface temperature recommended to retain aggregate
25 22 - 23 20 -21 18 - 19 16 - 17 -
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HEALTH SAFETY & ENVIRONMENT
• Occupational Health Safety ACT
• Injuries are costly
– Person
– Families
– Companies
– Workmen’s compensation
• Loss of Productivity
• Sabita safety training
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S-E 1 + 3% Fluxant (160 °C)
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S-E 1 + 3% Fluxant (160 °C)
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S-E 1 + 3% Fluxant (160 °C)
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Picture of exploded sprayer
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Guidelines in COLTO 4300-8
Grade ROAD
TEMP
AIR
TEMP
OVERNIGHT
TEMP
80/100 25 ? ?
150/200 21 ? ?
MC3000 10 ? ?
MC800 10 ? ?
Bitumen Emulsions 10 ? ?
Modified Bitumen Emulsion 10 ? ?
COLD APPLIED ALTERNATIVES
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What is a Bitumen Emulsion?
COLD APPLIED ALTERNATIVES
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50 microns
50
mic
ron
s
Microscopic image – bitumen emulsion x 1000
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+
+ +
+
+
+
+
+
+++
+
+
+
+
+
+
Cationic Spray Grade(CRS)
Bitumen droplet
0,20 to 0,30% emulsifier
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+
-
Anionic Stable Grade (SS)
+++
-++
1,0 to 1,5% emulsifier
-
-
-
- -
-
-
-
-
-
- -
- --
-
- -
-
-
-
-
--
-
- -
- -
-
-
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Grades of Bitumen Emulsions
Spray Grade / Rapid Set
Mix Grade / Medium Set
Stable Grade / Slow Set
R
M
S
COLD APPLIED ALTERNATIVES
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• Emulsions & modified emulsions can also be used to construct single & double seals
• Different construction approach will be required.
i.e.:
Single seal 1st spray a tack application
stone application
2nd spray a penetration application
Double seal stone application
3rd spray a penetration application
COLD APPLIED ALTERNATIVES
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Latex modification of bitumen
Bitumen emulsion SBR(Styrene-Butadiene-Rubber)
+
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Microscopic image – bitumen emulsion + 5% latex (1000 x)
50
mic
ron
s
50 microns
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Microscopic image – rubber latex (1000 x)
50
mic
ron
s
50 microns
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• Emulsions
– CRS60 {or CRS60(t)}
– CRS65 {or CRS65(t)}
– CRS 70 (made to order)
• Modified emulsions
– CRS60 / 3,5 (made to order)
– CRS65 / 3,5 (made to order)
– CRS 70 / 3,5 (made to order)
• Fog Sprays
– CRS 60 / 65 (Cationic)
– SS 60 (Anionic)
Notify Suppliers in time6-8 weeksDelivery of
Raw Material
COLD APPLIED ALTERNATIVES
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Coalescence – different stages
Stable emulsion Flocculation Densification Coalescence
Fluxants promote development of coalescence
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Coalescence – different stages
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“Fluxing” of bitumen emulsions
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For Cape Seals NO FLUX recommended!
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REQUIREMENT FOR FLUXING AGENTSSANS 4001-BT4 (Edition 1) (old SABS 548:2003)
Fluxing agents shall, when tested in accordance withMethod ASTM D86, comply with the following requirements:
(a) Initial boiling point: Not lower than 140 °C
(a) Distillate at 350 °C: Not less than 90% (v/v)
THIS PREVENTS SUPPLIERS TO INCORPORATE “ANY” SOLVENTS
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Determination of flux content (ASTM D244)
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Determination of flux content (ASTM D244)
Determination of flux content (ASTM D244)
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Determination of flux content (ASTM D244)
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Typical fluxant levels used in the Western Cape
November to February
March to April to May
June to AugustSeptember to
October
2% 3% 4 – 5% 3%
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Effect of fluxing on bitumen emulsions
• Improves dispersion
• Improves the “breaking” rate
• Quicker mosaic formation
• Improved viscosity
• Enhanced storage stability
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Disadvantages of unfluxedbitumens
• Poorer dispersion
• Poorer storage stability
• Slower mosaic formation
• Lower viscosity
• Delay in breaking during cold weather conditions
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Sedimentation of bitumen particles
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STOKES FORMULA
V =2
9
gr
2
(D-d)
η
Where:
V = rate of settlement
g = acceleration gravity
D = density of dispersed phase
d = density of dispersion medium
r = radius of particles
η = viscosity of aqueous phase
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Densities of fluxed bitumen
0.980
0.985
0.990
0.995
1.000
1.005
1.010
1.015
1.020
1.025
0 1 2 3 4 5 6 7 8 9 10
De
nsi
ty (
kg/l
)
Paraffin flux (%m/m)
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Freezing/Thawing of emulsions