uls~snshave bee

This document was produced by a subcomminee of the

and, to confirm its vaiid~tyin pracltce is clrculated in
being submitted to the CSRA for final approval.

B~Purnenemulsruns
TRO-47. Pretoria, 1994

ows In maintenance,

ation ( @ . grecyclin

tut-e, behaviour, te
intenance, re

1.,1

Background

Objectives and scope

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2,

"

2.1

General

22

Emulsion ~ngiedienls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ulsions

2
2.

ing a n d curing

25

asic properiles of e

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

haviskar of ernuls~ons .

. . . . . . . . . . . . . . . . . . . .

S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ion

CI

3.9

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2

Storage

3.3

General liandltng

3
35

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

pplicalions

Safety

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

eci

.................
. . . . . . . . . . . .

. . . . . . . . . . . .

43

Tests and specifications Conveniioi

4 4

Tests a n d specificalions Modified emuls~ons

emuis~ons

. . . . . . . . . . . . .
. . . .

23

. . . . . . . . . . . . . . . . . . . . . , . , . . . . .

lsion selection

. . . . . . . . . . . . . . . . , . . . . . . . . . . . . .

. .

. .

. .

. . . . . . .

. . .

38

38

. .

38

38

. . . . . . . . . . . , . . , , . . . . . . . , . , , . . . . . . .

"

39

. . .

and emwls~sn .

.3

ConsPmctlon . .
ints .

. . . .

. . . . . . .

. . . . .
.

. . .
.

. .

. . . .

. .

39
.

40

9-

Bare-coating sl aggrc? at@

9.1

General

9.3 @onstruction

. . . .

. . . .

. .

@onstiarn$s .

. . . .

. . . . . . . . . . . .

"

"

. . .

- .

. . . .

. . .

41

. . . . . . . , . . . . . , . . . . . .

44

. . . , . . . . . . . . . . . . . . . . . . . . . .

42

Singleseals

. . . . . . . . . . . . . . . . . . . . . . . . . .

43

Doubieseals

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . - . . . . .

45

Conventional slurry . .

. .

. .

. . . . .

. . . . . . .

. .

. . . . . . .

. .

. . .

apid-setting coarse slurry

Evaluatron a n d teslin

Background

1 2 . 2 Patch repair

1 2 . 3 Pothole repair
Crack l ~ l l e r

. .

. .

. .

. . . . . .
,

"

"

. . .

. .

. . .
. .

..

. . .

. . .

. .

. . . - . . . . . .

. . . . .

. . . . . .

. .

126

Finegiadedsiurry

. . . , . . . . . . . . . . . , . . . . . . . . . . . . . . . . , . . .

"f 2

s u r f a c e treatment

42 8

Dust pailiatrve

. .

.
.

. . . . . .
.

. . . . . . .

. . , . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . , - . . . . .

12.5 Fog spray

. . . . . . . . . . . . . . . . . . . . .

12.

12.4

"

. . . 41

. .

. . . . . . . . . . m . * . . . , . , . , . . . . . . .
.

. . . . . . . . . . . . . . . . . .

eseai

12.1

~ ~ e . . . . . . 8 0 ~ . . . . . . e . . . ~ . . a . . . 42
. . . . .

rnulsian s a ~ f f a e 2t r e a t r ~~~ 7

General

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2 Material a n d design

94

. . . .

. . . . . . .

. . . . . . . . . . .

_ . .

65
ace treatments

rtumen emulsions

70

3 1

Slorage tempeialuies for emulsions

32

Gurdehnes for cond121anrn of emptied tanks before load

33

Typical spray temperatures for emulsion and minimu

surface temperatures

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

ested conversion factors Pos dr

......................... 4

cold net res~duai

S specilicatlo
S speciflcations for
43
4

lsicsns . . . . . . . . . . . . . . . . . . . . . .
cationic emulstons . . . . . . . . . . . . . . . . . . . . . 2

er)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setectmn of t h e

(rnodhcation or

. . . .

81

Recommended spray rates for tac

18 1

Gsadrent I~rnitsfor emuls~on-

10 2

Suggested layer rhckness for h e , medium

:0 3 R e s ~ d u a lbinder
10 4

. . . . .

Irlterirn s p e c h c a t ~ o n sfor rec

emulsions (homogenous

51

rs)

lnleriin specif~cationfor rno

. . . . . . . . . . . . . . . S . . . . .

propellie

Criteria for t h e Marvil per

. . . . . . . . . .

gregate gradin

. . . . . . . . . . . . . . . . . . . . . .

12 3

Recomn-iended types of ernuision-base

degrees of crack rnovenxmt

. . . . .

r variou
. . . . . . . . . . . . . . . . . . . . .

$8

were first developed at the turn o

OS that they were used in th
use of bitumen emulsions
ber of types and

the early 1970s,

ide, contributed t
nstruction. The e
er-modified emulsi
ts realised by the use of bitume
? S , since emulsions are applied
bitumens, thus e
itumen emulsions r
cessity for drying is eliminated,

this manual is to provide

construction and maintena
is on the composition, manufacture,
n emulsions. The second
men emulsions in road wo

lines for the

is not intended to be used as

rnulsion mixes, etc.,
se of bitumen emulsion
ns and materials given in the
ut are merely indications of desuable properlies
ulsions are referred to s~rnplyas emuls~onsin !he remainder of this

ilturnen emulsions

n emulsion can

n-ionic emulsion

emuisions, therefore, consist of

basic components,

water;

64

flux~ngagents (optional)

The types of emuls~

a
G$

anisnlc emulsrfi

catlonrc: emulsifiers; or
non-ionic emcltsilrefs (

g. prime coats).

en emulsions
,

Pretoria, 199

rnuls~onin terms of their appi~catton

c t ~ v ~ character~stlcs
ty

emulsion may be modilie

The grades of anionic emulsions currenll

Cafmr~icern ulsions:
~lablein Sou
the speclficalions

(Specificatio
e referred to for

2.

-The g r a d e s of cationic emulsions currently av

rtunwrr emulsions
H7, Pretoria, 19

dified emulsions, the a

S , Sabita or the manuf
odified emulsion m

he composition o
omance, inclu

redients of emulsions

IS

essent~alto enable one to

t of ernuls~onsand ca

e s 60 Is '70per cent

revail, base bitu

d calcium ions
hich are insol

iluted in the fiel

pre-mix or stable grade).

mulsifiers must be chemically actwated

ctivated, emulsifiers are molecules that consis

en emulsion (antoni
of the functional gro
and anionic groups a
in has an a
ereas the ionic
ot to bitumen.

e surface of th

es how cationic ernulsifrers attach

') has penetrated int
ionic functional group (
emulsifier is initi
ain in the wate
ct these negatively c
ble layer". It is these
lobules in suspension.

Bitumen emulsions

L4 correspondiilg process occurs whe

an "eiectaicaf

The equlpinen! require to manufacture

shear mechanical mill (nor

her equipment I
for both the biturn

p u m p s , control valv
t h e ernuls~fiedwater.

itumen emulsions
W7, Pretoria, 199

ing process concurrent str

re-treated with a
he colloid mill.
o intensive shear stresses as they p
ay then be pumped
ernperature of the incornin
rom the heat exchan r the emulsion is then pu

ter

e,

ISPERSING PHASE

emulsion can be modified by either of two methods:

@I

n of emulsions: During this process t h e rnodtf~eris mixed with

ufactured emulsion. It is generally use
d can be mixed on site,

of the base bitumen: Dur~ngt h ~ sprocess t h e

prior to the ernulsifym process it 1s gener

S,although S

sition from emuisifled bin

bitumen emulsion io perlorm

process and occurs when th

FloccuSatsor.1 rs the first sta
dispersed binder lobules agglomerate into clurn S called flocs. Duri
ever larger globule
process of coales nce the floes stick logeth
a con!inclous mass of binder is pro
S

in normal u

rates the processes of flocc

tion and coalescence.

processes Emulsions to be used for t

B~turnenemulsions
TRW7, Pretoria, 199

hich affect the rate of breaking of bitumen e m u l s ~ o nare

ater content of the
er conditions

gregate in the mix,

oids content of the mix;

sidual binder content an

te of curing is a
en the emuls~o

nitude of the electrtcal char e of the aggregate in re1

as poor stone retent~on

ion of cernentitiou

iopriate will lacilllate a re

Some of t h e relevant pope

tract~onforces.

ion
Adhesion reflects

materials, such a

Once the f~rst cond~tion has been sat

ocess 1s referred to a s pas

Pion W

I)

6a

In th

I ? the
~

ionic nature of the e

la!~onshrpscan

nce of electropositive m

In t h e presence of electrone

etween these aggre

there is no r

tionic) nature of s

ggregates an

The v~scosily of ernuision is

apparatus.

Stokes' L a w .

mulsions are more complex than conventional

ring storage and
sphalt institute0'
in the use of emulsions and

g or storage of emulsions

e emulsion to be idnsul
irnple rules will save

lines on the storage of emulsion are given

@

63

ulsion should be stored in the s m e manner a s water, namely

10C and 60C, depending on use.
ed as the heating medium for storage tanks with
ssure waste steam
oil surface should no

t higher temperatur

t3

rature of the heatmg surface should not exceed 160'6

cess of this will cause premature breaking of the

means of pumps.
eS1

rosene or oil o

ould be provi

elines for general

a

of emulsion ar

When emulsions ar
or reduce s k m foarnat~on

k m e s should be bio n out and drain plugs should

they are no! in service

ntly to eliminat

ff

eS

(L

44

&B

@a

oper clearances
urnps can cause

g methods should be used to

o free a seized pump. Propa

cess heat should not be applied to the packin

ump may be damaged and the

should be warmed to about 65C to facilit

has been out of service for
the appropriate type of oil in
diluted, the compatibili
y testing a small quantity.

m water should be used for diluting.

ly to the emulsion.

recirculation should be avoide

and air may become

cb

ater should alw

vent foaming, inlet pipes and return lines s h o d

of tanks.
e4

(B

In order to minimize contamination from skinning

ormed, the emulsion should be pumped from the bo

ys be borne in mind that emulsions with t h e s

heir chern~stryan

db

ulsions should be transporte

in truck haulers

sates

grades of emulsions
slow-setting giade
E ~ U I S I O should
~ I S not be r e c i r c ~ ~ l a t efor
d [on
ach c o d d ren
@

mutsions should not be fo

rude oil

: Flush out

SW

precautions are gwen elsewhere'".

e used for the construct~onof surface treatr-wents, cold

ulsion-treated bases.

scussed in T R H ~ 'an
~ ' their constructton is
ions. However, aspec considered to

vision is sprayed, the primed bas

st, mud and fallen leaves
e used at ambi
m road temper
rely provides an

ion

r application rates

conversion factors pr
iven in Table 3.

ions for

rtumen emulsions

variations rn th

edormance o

spray lance is used (either f

rum pump on a trolley) the
an even crrccdlar motion an

re9

applied as follo

is carried out in a

mulsion Mixes (G
ng or mixing the e
material:
S

In dr%ufedform: rn this case the emulsion is dilut

water, spread over the gravel a n d mix
process.
: in this case the emulsion is

Brr

t h e n mixed r

%ionwater has been mix

avel according to t

Bitumen emulsions
W 7 , Pretoria, 11 99

circumstances should undiluie

his results in the
S loss in strengt

of this section does not include s

is intended mainly for the user of

lsions are used at a m

handling bitumen, i.

e
B

have comes into

Id be thoroughly washed

ling of emulsion an
use of oil insoluble
wever, it is stressed

on protective clothing are provided in t h e S a

entally spilled or lea

m ~ aon
l safety"',

If emuisron is inyeste
kept cairn and a doclor should be c a l k

not be made P:

hen emulsion C O e s into contact wtth t

viashed tiloroughly with cold water and
rernowed before it breaks. if the er-nulsa
paraffin should be u
(diesel) or halogen
dermatitrs Ali cant
if large amounts of ernuision come into co
break, the injured

If the emuisrun comes mta csntac

emulsions should be in acco

or emulsions, namely
r cationic emulsions.
scribed in the SABS spe
ction methods and met
nventional and rnodrf~e

or sampling emulsions is described in

ovide the batch num

ly u - ~ ~ as
ce
cosity of the blen
lux in the blend should be indi
influence the curing
n and consequently the timing of successwe operations
e-mouth jars or bo
mulsions should be
eta1 containers should not be used.
, the emulsion should be sample
ise, samples should be taken I

ing precautions should be a

%

pie containers should be ne

it together tightly.

solvent, nor should it be wiped

erial on the outsid
cloth immediate1

e3

itumen 'emulsions

mple should not be transferred into another container

ii

during shipment.

he tests to determine these properties are b r ~ e f l y

1: The viscosity of bitumen emulsions

iscometer. In this
ugh a standard orifi

of emulsion is pour
unt of bitumen in the
sieve is deternined.
ulsion should be so small that vi

quantity of ernulsio
cement. In the case of spr
oat the chips. In the case o
lsion should not break

ample of emulsion is pl
fter the centrifuge has
to its original quality.
of the jar) should occur.
resistance test:

rnulsions is evaluated.

ie specificallons for anionic a n d cationic

Tables 4 1 and 4 2.

allon, alter 60 cornpl

roPatasns

TRW7, Pretoria, 1

Grade
p
-

Property

Stable
rni x
6 09'0

5 1-200

50
(rnax)

inder content,

(m/m)

OO
/

Fluxing agent content,

OO
/

STM D2

6 5 -68

60-63

STM D244

5 rnax

n~l

0,25

0,25

( d m )of binder
ssidue on sieving,

ore

Pos
Pos

ure

1,o
zathode after 30 min, g
n~l

n~l

zomplets rotations

2,c

Soagulation value, %
$dm) :
Silica flour, max

s may be used to recover the base

itumen from an

@?

!he preparation is completed within 15 minutes.

The foliowing test are normally conducte

a standard n

Ductility test: The ductllit

m ~ l l ~ m e t r eto
s which a st
c o n d l t ~ s n sbefore t h e thr
cohesiveness or a
applied ioa

ia
same as those described in sect~on
io

r content, %, (min).

ue on sieving, g/100 rnl,

me as those described in section

se described rn section 4 . 3 3 In
means of a ductitorneter The

!ion, the elastic recovery

hod is b i ~ e f i ydescribed

96 recovery = (200- "elongation (m

rope

iven tn t h e Sabita

s d material satisfies
ual'"', these mixes a

engineering properties.

e behaviour of
-component sy
re multi-cornpone
ired) lime or c

MS is mors CO
rns comprising
ystems contain

alt is a visco-elastic materi

aunt of the si nificant influence of curing, its

should be considere in both the mix

tructed in South

lastic materials

Bitumen emulsion

sign equrprr~enta s iequlred for granular

ce include:

both initial an

curing.
@

Bitumen emulsions
TRH7, Pretoria, 1994.

layer is defermined from fatigue curves and

tails of construction and qual~tycontrol are given in ih

levant clauses of the CS

re considered significant in the

the modification approach is use

should preferably be lower (10
mi~ures);
r no circumstances should undilute

smulsion corns into

number of factors that may influence the decision to use

MS, unrestricted t
. Provision should
) . The length of this
of cement, type of ag

n case of srtabiilse

to prevent tr

(DCP) measurements coul

rd materials in
n approach) may b
of aggregates (of di
calsicn, lime and cerne

vwth ernutsions shoul

itumen emulsions

h e selection of the type and i;:zde of prirr2e and

e o i granular layer, !is absor
t of the base

itumen emulsions

ot possible to cover t h e cemented layer

cing within 24 hours, a curing mernbra
ose of this curing rnembr

any detrimental c
of membrane to pr

nation or salt migration

inders for curing membranes are

e section 2.1.

e curing membrane should

menled layer. Suitable spray
cornmended spraying temper
re should be taken (such as by proper brooming) to ensur

een the curing membrane and a cemented

vent any subsequent slippage causing ailure of bituminous
tails of the construction of curing

seal approach is recommended.

cing.

sodace or concrete

emulsion shoul
ich emulsion may h
emulsion before the asphalt i

coals should not be

riods of cold of

est conditions are when t

ising and when there

air temperat

ept off the tack coat prior to placeme

speed limit should be kept belo

itumen emulsions

umew content

Bitumen emu!sions
7 , Pretoria, 1994.

versely affect the s

prior to the ap

6s

ours should ap
of emulsions,
se should be cons1
unless the moistu
less than 50 per cen

ing types of single seals

B~tumenemulsions

ith emuisior 5 a i e commor7iy used:

lection and application of the appropri

,75 mm chips re also used for t
on low-volum

ri
ates should conform to t

relaxation rn fines an
gates. The mate

should not be pr
characteristics of

h e aggregates used in sea

used for spraying. The abso
cilitates the breakin

tionc spray grade (65 or 70%) emulsions or S

ommended for use in single seals.

ulsions

with absorptive a

-modified emulsions pe

mulsions are mainly

11s of the design of single seals

TRW7, Pretoria, 199

here seats are la

rtumen
FM?, P

iontc (65% or 70%) spray grade or S

0th applications of t
e use of anionic S
breaking characteristics.
ray consists of either stable grade
e been diluted in water, Cationic
ich has been diluted in water (r

e section 10.2.1 for details of aggregales nd of the use of

ulsions.

etails of the design of double seals are given in T

elines given in section 10.2.3 should

ient time should elapse prior to the application of

e that all the volatiles or water in the first spray hav
es are trapped by t h e second spray, bleeding or rich

See also section 10.6.

sists of the applic

affic volumes, 13.2 mm aggregate

slurry may be used.

or 13,2 mm a
r the slurry sho
tandard Specif
slurry should contain a Portland cement active filler
71
or an approved alternative.

ith

for

ion

Construction of C

B~tumenernulsrons
TRH7, Pretoria, 199

r of slurry shoul

are used for tr

n y of the following defects:
e

uneven surfaces because of bumps and ru

fine slurries are no ally applied as su

case of active crac s, the use of

ate requirements are

s is discussed in TR

machine shoul

ute the weight of

urs to the existing
the slurry uniform!
improved by mea

brooming.

s should be included
reference to joints a

slurry, ihe road should be kept close to f f a f k M-M

1. This may vary from 1 hour on warm d a y s to 4

hen rain is imminent.

ecome unstable under traffic

layers thicker th

tions of high tra ic volumes and (

polymer-modifi
slurries (section

Q
B

ere the surface is uneven because o

the edges of the surfacin
the sodace texture nee

B
0

slurries can to
and also und

slurries can be u
slurries can be placed on the
er is normally capable of ca

ictated by the sp

to 20 mm. Type 2 gradings (ma

earing courses, edge breaks and for

cement confor

supplier.)
has been laid, the residual binder should have ih

slurries shou
In additron, t
be capable of

iturnen emulsions

in

ithin the spreading systems

recommended to assess t
bility test and visual assessm

oad temperatures at the time of placing should not excee

e Vlalit adhesion test

Is constructed with e
lsions are given Tabl
emulsion is co d onto 200 x 200 mm steel
lates being coated. l00 st
roject are placed (ev
ioned In an oven at 50"
5C and the rern
ced in a cooling c

of siurries can be determined with th

or s,mply called the Cone test. This test
value to consistency.
,

is lest uses t h e sand absorption cone (

cone is a hollow 0,8 mm frustum, 75
rs. The flow scale has
s t r ~ at~le,
l
metal sheet or pa

ion or

ixed asphalt cures relative1

thorities. It is normally used
alt is unsconomical on ace
e asphalt plant. Open-graded cold-rni
ks and for patching.
attonic pre-mix grade emulsions with
ally used for open-graded cold-mixed
nionic as well as cationic stable grade emulsion can be U
ixes containing a large proportion of fine material. It
than the mixes prepared with cationic pre-mi

-mixed asphalt is nomally seale

ulrs in a relatively impermeable surfacin

~turnenemulsions

ce operations can inc ase both the functtonal and

. in this section th use of emulsion in mai
atch repair, pothole repair, crack filling and ge

efined as any rehabilitation work to pavement layers to

an area of typically less than 50 rn2 andor having a I

nusual to see maintenance teams repeatedly patchin

auses for the poor perfomanc
ackfill material
ent methods (if

as devised using sound techniques t

terial and can be
been successfully irn

rninous surfacing.

xcavation should be
stone material should
small concrete mixer. Then the backfill
in thin layers; no
rum rollers or no more than 60 mm for pla

n used to control th

ntial for the f ~ n

ood bonding of the ne

n imperneable
tch work and especially to the existing surfacing.

ulsion-based mlxes used for mainten

conventional as halts in that hot-rni
uction. These mi s may be store
othole repairs can be divided into
@

$a

mixes for immediate use, and

mixes for long-term storage.

ixes consist of bout 5 to 10

ulsion (by mass of total mix) wi

ants, small truck mixers or

nt, anionic or

etails of various types

s should b e cleaned by

itumen emulsions
TRH7, Pretoria, 1994

rat -filled emulsions

on-attainment of specified densiti

ucts are also used to ens

lications of diluted (mo

muisions or cationic sp
enrichment measures
constructed single seal surface treatment
loss. The purpose of fo seals is to improve the
sprays are light a

ce is dampened prior to a
sion to flow around the ag

is mainly used for surface-te

due to an absenc

ue to excess voids.

for fine siurries should con

le 12.2. Goldmin
Hect~velyin the manufactu
ulsion content for fine slurries is gen

itumen emulsions

slurries shoul

The guidelines

Brtumen emulsions
TRti?, Pretoria,

O F @ than

ction 10 apply

3 months.

amounts of dust are created by vehicles on unpaved

reasons for the accident rates on unpaved roads
than those on sudac
The use of emulsions as dust palliatives is a ractical and econo
cationic emu1
to this problem. Diluted stable-gra
irectly onto the unpaved road S
rnulsion is d~luted
emuision is applie
ication depends on the condition of t

ears t h e emphasis

g existing paverne

slab1
a wit

c
iS

benefits:

vents their loss

-

ce of t h e sod they ca
rates a s the

There are other mulch tr

roaches, s u c h as using slraw and h a y in

Authorities. 1987.
epartrnent of Tran

Testing and Materials. 1989.

ureau of Standards.

rican Bitumen and Tar Association. 1993.

. Manual 14. Cap

rch. 1985.
-

~turnensmulsions

phase

arshall testinn at 23 Rr

fluid content (

'ure for 45 hours @ 60

itumen emulsions