April 2004

TECHNICAL NOTE 15 FOAMED BITUMEN SPRAYED SEALING

Supersedes APRG Technical Note 1, March 1993

Introduction Foamed bitumen sprayed sealing was introduced into Australia in 1993. An APRG Technical Note (No 1) was prepared in conjunction with initial field trials in March 1993. The purpose of this revised Technical Note is to provide an update of the subsequent development and current status of foamed bitumen sealing in Australia. What is Foamed Bitumen Addition of water to hot bitumen will create foaming from water vapour trapped within the bitumen. The foamed bitumen process was developed by Mobil in the 1960s as a means of dispersing bitumen into cold materials without the use of cutter oils or emulsification of the bitumen. The foaming process is regulated by the rate of addition of water and the use of surface-active agents to control the foaming characteristics of the bitumen. These factors determine the volume of expansion and rate of collapse of foam. Foamed bitumen has been successful in stabilising of granular materials and cold recycling of asphalt and foamed bitumen stabilising processes. These processes remain in regular use in Australia. Application of the foamed bitumen concept to sprayed sealing was undertaken in France by Enterprise Jean Le Febvre (EJL) in conjunction with Mobil Oil France. In the 1990s it was reported that some 2 million square metres, annually, of foamed bitumen were being applied to pavements in France. Foamed Bitumen Sprayed Sealing A specially constructed foam spray distributor (Figure 1) must be used to manufacture and apply the foam bitumen. Each jet is has a controlled expansion chamber that ensures acceptable transverse distribution across the spraybar as well as safe handling of the bitumen water mixtures. The proportioning of components is critical for well controlled foaming. Sealing aggregate is spread as the foam begins to collapse. This critical timing allows the remaining foam to collapse around the cover aggregate ensuring good adhesion. The active agents in the foam also act as antistripping agents which assist in promoting adhesion to both the aggregate and the pavement. Normal rolling with pneumatic wheeled rollers completes the process. The bitumen phase of foamed bitumen may be class 50, 170 or 320 bitumen complying with AS 2008, selected on the same basis as with conventional sealing. The chemicals used in the bitumen and water phases are proprietary surfactants selected by the supplier. The aggregate used should be high quality, clean, precoated and dry.

Figure 1 Spraying foam bitumen

Characteristics of Foamed Bitumen Sealing Compared to conventional sealing binders, foamed bitumen has the following characteristics: The short-term low viscosity of foamed bitumen allows sealing when pavement temperatures are as low as 15C without the use of a cutter oil. A wide range of binders, including modified bitumens, can be applied without the complication of cutter oils. The foaming process permits the aggregate particles to remain mobile for longer than conventional binders do, and this allows the rapid formation of a shoulder to shoulder mosaic under the actions of rolling and traffic. Aggregate wetting and retention can be improved. Foamed bitumen sealing creates no hydrocarbon emissions from the evaporation of cutter oils hence greater energy efficiency and improved environmental outcomes, particularly in urban areas. Reduced transport cost due to elimination of cutter oil and water compared to cutback and emulsion sealing respectively.

Binders used for surface enrichment traditionally involve cutback bitumen or bitumen emulsion. It was found that foamed bitumen was effective in surface enrichment work. Foaming provides sufficient fluidity to flow into void spaces around aggregate particles and rapid cure reduces risk of binder pick-up in early trafficking. With the only additive being the chemical surfactant, it is costeffective compared to cutback bitumen and bitumen emulsion. In surface enrichment work the critical period for application of cover aggregate does not apply. Foamed bitumen surface enrichment work was used for some time in parts of Western Australia and Northern Territory but is now discontinued as a commercial process.

Use of Foamed Bitumen Sealing in Australia Following success of the initial trials in 1993, one bitumen sprayer was manufactured for use in Australia and initially went into service in Western Australia. It was soon found difficult to reliably control the rate of collapse of the foam in all conditions. The critical feature of foamed bitumen sealing is the application of aggregate while the bitumen is still in an expanded state. This requires precise timing of aggregate spreading. A delay in spreading could result in aggregate being spread on relatively immobile bitumen binder and hence poor adhesion and limited aggregate reorientation and embedment by initial rolling. It was decided that the extra cost of equipment, additives and process control, and associated risks did not outweigh the advantages of not using cutter oils. The process is not currently used for sprayed sealing in Australia. Foamed Bitumen for Surface Enrichment Surface enrichment is extensively used for the maintenance of sprayed seals, particularly in remote areas where seals largely deteriorate from a combination of weathering of bitumen binder and absorption of binder into underlying pavement materials. Application of additional binder can effectively extend the life of a sprayed seal for a number of years.

Figure 2 Timing of Aggregate Spreading is Important

For further information please contact Walter Holtrop Australian Asphalt Pavement Association Tel (03) 9853 3595 Fax (03) 9853 3484 Ray Gaughan Roads and Traffic Authority Tel (02) 8814 2101 Fax (02) 8814 2312