U.S. patent application number 13/050649 was filed with the patent office on 2012-03-15 for method for bonding prepared substrates for roadways using a low-tracking asphalt emulsion coating.
This patent application is currently assigned to BLACKLIDGE EMULSIONS, INC.. Invention is credited to Roy B. Blacklidge.
Application Number | 20120063843 13/050649 |
Document ID | / |
Family ID | 38067821 |
Filed Date | 2012-03-15 |
United States Patent
Application |
20120063843 |
Kind Code |
A1 |
Blacklidge; Roy B. |
March 15, 2012 |
Method For Bonding Prepared Substrates For Roadways Using A
Low-Tracking Asphalt Emulsion Coating
Abstract
A method for bonding together an existing substrate layer and a
pavement layer, such that a strong adhesive bond is formed by using
a tack coat, provided by an asphalt emulsion, in between the layers
as the bond coat. The tack coat layer is a low-tracking coating
which cures quickly such that the pavement layer may be applied to
the substrate, hours to days after the emulsion is applied to the
substrate. The asphalt emulsion comprises at least a first phase of
from about 30% to about 70% of an asphalt composition, about 30% to
about 70% water, and about 0.1% to about 3.0% emulsifying agent,
stabilizer and/or additives, or 0.1% to about 30% if polymeric or
other additves are also included.
Inventors: |
Blacklidge; Roy B.;
(Gulfport, MS) |
Assignee: |
BLACKLIDGE EMULSIONS, INC.
Gulfport
MS
|
Family ID: |
38067821 |
Appl. No.: |
13/050649 |
Filed: |
March 17, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12403181 |
Mar 12, 2009 |
7918624 |
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13050649 |
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11561804 |
Nov 20, 2006 |
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12403181 |
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60738319 |
Nov 18, 2005 |
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Current U.S.
Class: |
404/31 ;
427/138 |
Current CPC
Class: |
C08L 95/005 20130101;
Y10T 428/31815 20150401; C08L 95/005 20130101; E01C 7/185 20130101;
C08L 2666/74 20130101 |
Class at
Publication: |
404/31 ;
427/138 |
International
Class: |
E01C 3/00 20060101
E01C003/00; E01C 7/04 20060101 E01C007/04; E01C 7/06 20060101
E01C007/06; B05D 5/10 20060101 B05D005/10 |
Claims
1. A method for bonding a layer of pavement material to a substrate
of paving materials, soil, clay, sand, shell, cement, limestone,
fly ash or mixtures thereof, the steps comprising: providing an
emulsion with at least a first phase of an asphalt composition, a
second phase of water, and emulsifying and stabilizing additives,
the asphalt composition selected to provide a coating having a
penetration value less than about 40 dmm and a softening point
greater than about 140.degree. F. (60.degree. C.) when applied to
the substrate and cured; applying the emulsion to an exposed
surface of the substrate at a rate sufficient to provide a coating
having an amount of the asphalt composition effective to bond the
pavement layer to the substrate; providing the pavement materials
for the paving layer heated to a temperature sufficient to soften
the coating an amount effective to form a bonding surface on an
exposed surface of the coating; applying the pavement material to
the exposed coating surface to form a pavement layer and to soften
the exposed coating surface forming a bond between the pavement
layer and the substrate.
2. The method of claim 1 wherein the asphalt composition phase
comprises a hard pen asphalt composition with a penetration rating
less than about 40 dmm and a softening point greater than about
140.degree. F. (60.degree. C.) when applied to the substrate and
cured.
3. The method of claim 2 wherein the hard pen asphalt has a
penetration rating of less than or equal to about 15 dmm, and a
softening point temperature of at least about 150.degree. F.
(66.degree. C.).
4. The method of claim 2 wherein the asphalt composition phase
comprises from about 30% to about 70% of the total weight of the
emulsion.
5. The method of claim 2 wherein the water phase comprises from
about 30% to about 70% of the total weight of the emulsion.
6. The method of claim 2 wherein the emulsifying agent further
comprises stabilizers, additives, and polymers, and comprises from
about 0.1% to about 30% of the total weight of the emulsion.
7. The method of claim 2 wherein the emulsion is applied to the
existing substrate layer in one or more applications having a total
application rate of about 0.01 to about 0.20 gallons per square
yard.
8. The method of claim 1 wherein the emulsion is applied to the
existing substrate layer at a temperature of about 140.degree. F.
to about 180.degree. F.
9. The method of claim 1 wherein the emulsion is applied to the
existing substrate layer at temperatures not exceeding about
212.degree. F. (100.degree. C.).
10. The method of claim 1 wherein the pavement material is heated
to a temperature sufficient to heat the exposed surface of the
coating to a temperature greater than about 140.degree. F.
(60.degree. C.) when the pavement material is applied to the coated
substrate.
11. The method of claim 9 wherein the pavement material is a hot
mix asphalt heated to a temperature greater than at least about
212.degree. F. (100.degree. C.).
12. The method of claim 1 wherein the asphalt composition of the
first phase is selected to provide cure time of the emulsion from
about 5 to about 60 minutes; and the coating applied to the
substrate is allowed to cure for at least the cure time to form a
traffic bearing surface before the pavement layer is applied to the
substrate.
13. The method of claim 2 wherein the emulsion is prepared at a
temperature of less than about 212.degree. F. (100.degree. C.).
14. The method of claim 1 wherein an emulsion is provided
comprising at least a first asphalt composition phase comprising a
mid to soft pen asphalt composition having a penetration value
greater than about 40 dmm and a softening point less than about
140.degree. F. (60.degree. C.) and additives effective to provide a
coating including at least the mid to soft pen asphalt composition
and said additives, the coating having a penetration value less
than about 40 dmm and a softening point above about 140.degree. F.
(60.degree. C.) when applied to the substrate and cured.
15. The method of claim 14 wherein the additives are polymeric
compositions selected from at least the group of EVA, SBS, SB, SBR,
SBR latex, waxes, polychloroprene, isoprene, polybutadiene, acrylic
and acrylic copolymers.
16. A method for forming a low-tracking tack coating capable of
bearing traffic without significant loss of bonding strength on a
substrate of paving material, soil, clay, sand, shell, cement,
limestone, fly ash or mixtures thereof, the steps comprising:
providing an emulsion with at least a first phase of an asphalt
composition, a second phase of water, and emulsifying and
stabilizing additives, the asphalt composition selected to provide
a coating having a penetration value less than about 40 dmm and a
softening point greater than about 140.degree. F. (60.degree. C.)
when applied to the substrate and cured; applying the emulsion to
an exposed surface of the substrate at a rate sufficient to provide
a coating having an amount of at least the asphalt composition
effective to bond the pavement layer to the substrate; and exposing
the coating to the atmosphere for a time sufficient to cure the
coating.
17. The method of claim 16 wherein the asphalt composition phase
comprises a hard pen asphalt composition with a penetration rating
less than about 40 dmm and a softening point above about
140.degree. F. (60.degree. C.) when applied to the substrate and
cured.
18. The method of claim 17 wherein the asphalt composition phase
comprises a hard pen asphalt with a penetration rating of less than
about 40 dmm, and a softening point temperature of at least about
140.degree. F. (60.degree. C.).
19. The method of claim 17 wherein the asphalt composition phase
comprises from about 30% to about 70% of the total weight of the
emulsion.
20. The method of claim 17 wherein the water phase comprises from
about 30% to about 70% of the total weight of the emulsion.
21. The method of claim 17 wherein the emulsifying agent further
comprises stabilizers, additives, and polymers, and comprises from
about 0.1% to about 30% of the total weight of the emulsion.
22. The method of claim 17 wherein the emulsion is applied to the
existing substrate layer in one or more applications having a total
application rate of about 0.01 to about 0.20 gallons per square
yard.
23. The method of claim 16 wherein the emulsion is applied to the
existing substrate layer at temperatures not exceeding about
212.degree. F. (100.degree. C.).
24. The method of claim 16 wherein after the coating is cured and
has been exposed to vehicular traffic, a pavement material is
applied to the exposed surface of the coating at a temperature
sufficient to heat the coating to a temperature greater than about
140.degree. F. (60.degree. C.) and effective to soften the coating
surface to provide a bonding interface between the pavement
material and the coated substrate.
25. The method of claim 24 wherein the pavement material is a hot
mix asphalt heated to a temperature greater than at least about
212.degree. F. (100.degree. C.).
26. The method of claim 16 wherein the asphalt composition of the
first phase is selected to provide cure time of the emulsion from
about 5 to about 60 minutes; and the coating applied to the
substrate is allowed to cure for at least the cure time before the
pavement layer is applied to the substrate to form a traffic
bearing surface.
27. The method of claim 16 wherein an emulsion is provided
comprising at least a first asphalt composition phase comprising a
mid to soft pen asphalt composition having a penetration value
greater than about 40 dmm and a softening point less than about
140.degree. F. (60.degree. C.) and additives effective to provide a
coating including at least the mid to soft pen asphalt composition
and said additives, the coating having a penetration value less
than about 40 dmm and a softening point above about 140.degree. F.
(60.degree. C.) when applied to the substrate and cured.
28. The method of claim 27 wherein the additives are polymeric
compositions selected from at least the group of EVA, SBS, SB, SBR,
SBR latex, waxes, polychloroprene, isoprene, polybutadiene, acrylic
and acrylic copolymers.
29. A pavement structure comprising a substrate of paving material,
soil, clay, sand, shell, cement, limestone, fly ash or mixtures
thereof, at least one layer of paving material, as at least one
bonding layer between the substrate and the paving material layer,
the bonding layer formed from an emulsion having at least a first
phase of an asphalt composition, a second phase of water, and
emulsifying and stabilizing additives, the asphalt composition
selected to provide the bonding layer with a penetration value less
than about 40 dmm and a softening point greater than about
140.degree. F. (60.degree. C.) when cured.
30. The pavement structure of claim 29 wherein the bonding layer
comprises a hard pen asphalt composition with a penetration rating
less than about 40 dmm and a softening point above about
140.degree. F. (60.degree. C.).
31. The pavement structure of claim 30 wherein the asphalt
composition comprises a hard pen asphalt with a penetration rating
of less than about 40 dmm, and a softening point temperature of at
least about 140.degree. F. (60.degree. C.).
32. The pavement structure of claim 30 wherein the asphalt
composition phase of the emulsion comprises from about 30% to about
70% of the total weight of the emulsion.
33. The pavement structure of claim 29 wherein the emulsion was
applied to the substrate layer at temperatures not exceeding about
212.degree. F. (100.degree. C.).
34. The pavement structure of claim 29 wherein the bond between the
pavement layer and the substrate is formed by heating the bonding
layer with the paving layer to a temperature greater than about
140.degree. F. (60.degree. C.) providing a bonding interface
between the pavement layer and the substrate.
35. The pavement structure of claim 34 wherein the pavement
material is a hot mix asphalt heated to a temperature greater than
at least about 212.degree. F. (100.degree. C.).
36. The pavement structure of claim 29 wherein additional pavement
layers are added to said pavement layer, and a bonding coating
formed by the emulsion is disposed between each layer to provide a
bonding interface as each layer is applied.
37. The pavement structure of claim 29 wherein the bonding layer is
formed from an emulsion with a first asphalt composition phase
comprising a mid to soft pen asphalt composition having a
penetration value greater than about 40 dmm and a softening point
less than about 140.degree. F. (60.degree. C.) and additives
effective to provide a bonding layer, the bonding layer having a
penetration value less than about 40 dmm and a softening point
above about 140.degree. F. (60.degree. C.) when cured.
38. The pavement structure of claim 37 wherein the additives are
polymeric compositions selected from at least the group of EVA,
SBS, SB, SBR, SBR latex, waxes, polychloroprene, isoprene,
polybutadiene, acrylic and acrylic copolymers.
Description
FIELD
[0001] This invention relates generally to a method providing an
adhesive tack coat for use between pavement layers, such as between
layers of asphaltic compositions or between layers of asphaltic
materials and other paving or base materials.
BACKGROUND
[0002] Many pavement structures comprise multiple layers of
pavement compositions that are applied to a prepared base or
foundation. Such pavement structures may include successive layers
of pavement materials applied to a base or foundation to build a
multi-layer composite structure suitable for use as a vehicle
roadway, parking lot or other similar traffic bearing structure. In
many instances, such multi-layer structures may comprise one or
more layers of asphaltic materials applied to a first, second,
third or successive pavement layer. The asphaltic layers typically
comprise a binder material containing asphalts, tars and/or other
binders, an aggregate rock, shell, recycled pavement materials, or
similar materials, and various additives, fillers, etc.
[0003] In constructing pavement structures with one or more
asphaltic layers, it is often necessary to lay each asphaltic layer
down on a preceding pavement layer in a predetermined sequence,
with a bonding material between the layers. The bonding material,
which also may be referred to as a tack coat, acts to provide a
degree of adhesion or bonding between the layers, and in some
instances, may fuse the layers together. The tack coat also acts to
reduce slippage and sliding of the layers relative to other layers
in the pavement structure during use or due to wear and weathering
of the pavement structure.
[0004] Pavement and road surfaces also require regular maintenance
to repair normal wear and tear of the roadway due to vehicular or
pedestrian traffic, the effect of weather and environmental
conditions, and other factors. In some applications, all or a
portion of the traffic bearing surface may be removed through
grinding, stripping or other means, and a new pavement layer is
applied to the prepared structure. In other applications, a new
pavement layer is placed down on top of the existing pavement
structure to provide a new or renewed traffic bearing surface. To
prepare such preexisting pavement structures for application of an
additional, new pavement layer, a tack coat often is applied to the
preexisting pavement surface to encourage the adhesion and/or
fusion of the new pavement material with the preexisting surface
and/or structure.
[0005] In many instances, the bonding and/or slippage resistance
provided by a tack coat is important during the construction of the
pavement structure, as well as in the completed structure. As the
pavement is constructed, it is important to avoid dislocation of
all or portions of the substrate layers as each successive layer is
applied to form the structure. Such damage can be significant at
the edges of a roadway, which often are not compacted as well as in
the middle of the roadway. In many applications, construction
vehicles, or other vehicles are permitted to travel over the
partially constructed structure, which also may exert stress on the
layers that have been applied to form the roadway causing slippage
or shifting of the layers.
[0006] A tack or bonding coat also may be applied to a base or
substrate layer in advance of the application of the next pavement
layer. In the meantime, construction or other vehicles are expected
to travel over the tack coat without significantly damaging or
reducing the effectiveness of the coating. Such damage often
occurs, however, when the tack or bonding coating is picked up on
the tires or tracks of vehicles traveling over the coated surface.
Where this occurs, the asphalt compositions often are tracked onto
other pavement surfaces causing disruption to the surrounding area.
This tracking also reduces the effectiveness of the tack coat by
displacing a portion of the intended volume from the area awaiting
a new pavement layer.
[0007] Insufficient adhesion between a new layer of pavement and an
existing base course, a previously laid pavement layer, or a
prepared pavement surface can cause pavement separation and
cracking during construction of the structure, as well as
subsequent failures and premature deterioration of the pavement
structure and/or surface. Such conditions often require costly
repairs, can cause damage to vehicles traveling on the surface and
may cause dangerous traffic conditions threatening damage to
property and injury to vehicle passengers.
[0008] The tack coats typically used in the construction of
asphaltic pavement structures are asphalt containing compositions
that are prepared as a liquid, flowable, fluid so that they can be
effectively and efficiently applied and spread over a prepared base
course or pavement surface. Such asphalt bonding compositions can
be liquefied in several ways, such as by heating above their
melting temperatures, dissolution into solvents or volatile oils to
form cutback asphalt compositions, and by emulsification with
water. In the case of cutback asphalt compositions, the cutback
becomes "cured" as solvents evaporate leaving the desired asphalt
composition.
[0009] To provide suitable bonding, tack coatings must provide an
adhesive, tacky surface after the composition, emulsion or coating
is cured to bond and/or fuse the pavement or pavement and base
layers. The asphalt materials available for use in tack coats are
commercially available in different standard grades, with different
properties, based on their viscosity, solids content, chemical
composition, and other characteristics. One grading measure is the
penetration or "pen" value.
[0010] The pen value is based on penetration testing where the
relative hardness of the asphalt composition is determined at a
predetermined temperature, typically about 77.degree. F.
(25.degree. C.). One test uses methods such as those described in
ASTM D5 (ASTM International) and AASHTO T49 (American Association
of State Highway and Transportation Officials). This test measures
the distance in dmm (tenths of a millimeter) that a standard
needle, under a standard loading, will penetrate a sample in a
given time under known temperature conditions. The resulting
distance is often referred to as the penetration or "pen"
value.
[0011] Another common measure of asphalt compositions is the Ring
and Ball Softening Point. This softening point test using methods,
such as those described in ASTM D36 and/or AASHTO T53, measures the
temperature at which an asphalt composition becomes soft and
flowable. As used herein, pen values and softening point values are
with reference to the above identified ASTM and AASHTO methods or
their equivalents.
[0012] Although not formally defined, typically hard (i.e. high
melting point) asphalt compositions have pen values of about 40 dmm
or less, with softening points greater than about 140.degree. F.
(60.degree. C.). Such compositions are often referred to as hard
pen or low pen asphalt compositions. Asphalt compositions with pen
values between about 40 dmm to about 100 dmm, and with softening
points between about 118.degree. F. (48.degree. C.) and about
140.degree. F. (60.degree. C.), are typically referred to as
medium, mid, or moderate pen asphalt compositions. Asphalt
compositions with pen values greater than 100 dmm and with
softening points less than 118.degree. F. (48.degree. C.) are
typically referred to as soft or high pen asphalt compositions.
[0013] The asphalt compositions often used to form asphalt
emulsions for the purposes of forming tack coats typically are soft
or medium pen asphalt products. They typically have pen values
greater than 40 dmm and softening points less than 140.degree. F.
(60.degree. C.). When applied as a tack coat, emulsions using such
soft or medium pen asphalt compositions typically provide a
relatively sticky, tacky surface under ambient temperature
conditions in pavement construction environments. As a result, such
tack coats experience significant tracking problems, and may not
provide a durable bond between paving surfaces, particularly at
elevated temperatures.
[0014] Hard pen asphalt compositions (i.e., penetration value of
less than about 40 dmm and softening points greater than about
140.degree. F. (60.degree. C.)) have not been used as tack coats in
pavement construction due to their high melting points, their
limited flowability and very low surface tackiness at ambient
temperatures for pavement construction. For example, hard pen
asphalt compositions often must be heated to temperatures as high
as 400.degree. F. (204.degree. C.) before they become sufficiently
flowable to be applied by spreading or spraying, and will have
little, if any, surface tackiness when cooled to ambient
temperatures for pavement construction. It is normally impractical
to maintain hard pen asphalts at such high temperatures for
application as a tack coat.
[0015] Hard pen asphalt compositions, in addition, are
significantly more difficult to emulsify than mid to high (i.e.,
medium to soft) pen asphalt compositions. Because of their high
melting temperatures, hard pen asphalt compositions typically must
be heated to relatively high temperatures prior to emulsification,
thus often resulting in undesirable emulsion temperatures above the
boiling point of water (212.degree. F. (100.degree. C.)). The use
of such high temperatures can interfere with the emulsification
process, often is impractical in preparing most asphalt containing
emulsions, and frequently produces emulsions with undesirable
particulate contents and other defects. Additionally, hard pen
asphalt emulsions often become unstable during storage and,
therefore, must be used shortly after they are prepared. This also
renders such products impractical as a tack coat in pavement
construction.
[0016] Hard pen asphalt compositions and emulsions also have been
used in applications where a high melting point is desirable. For
example, hard pen asphalt compositions have been used in roofing
materials and certain types of asphalt containing sealing
compositions. Hard pen asphalt emulsions also have been mixed with
clays and sands for use as a seal coating for the exposed surfaces
of parking lots and the like.
[0017] As a result, cutback asphalts, asphalt emulsions using mid
to soft pen asphalts, and mid to soft pen asphalts alone are
commonly employed as tack coats for bonding asphaltic pavement
materials to preexisting pavements, intermediate pavement courses,
and base courses in new construction. Cutback asphalt tack coats
typically included asphalt residues in excess of 60% by weight of
the total product combined with solvents such as naphthas,
kerosenes, oils or other such products to maintain the asphalt
compositions in a liquid, flowable condition. The conventional
asphalt emulsions typically included products with asphalt residues
in a range of from about 25% to 70% or greater by weight of the
total product.
[0018] A number of difficulties, however, limit the utility of
cutback asphalts and conventional asphalt emulsions made with
moderate or soft pen asphalt compositions. Some such products can
require a relatively long cure time (as long as 2 to 7 days or
more) before traffic is permitted to pass over the treated area.
Where the next pavement layer cannot be laid down immediately, the
cured tack coat remains exposed for extended periods and remains
tacky and sticky. Accordingly, vehicle traffic over the treated
surfaces often must be shut down until another layer of pavement is
applied, and if traffic is allowed to pass, the asphalt tack
coatings frequently adheres to the tires and tracks of vehicles
traveling over the coated surfaces. This frequently results in
lifting and damage to the tack coat and undesirable tracking of the
coating to other surfaces via the vehicle tires and tracks.
[0019] Damage to the tack coating can substantially interfere with
the ability of the coating to properly bond and/or fuse the
pavement layers or base together. As a result, the pavement layers
may slip or separate with the passage of traffic over the structure
and time. This type of damage also may permit water penetration
into the pavement surface, which can result in further
deterioration due to freeze-thaw cycles or similar stresses. As a
result, multiple applications of the tack coat may be required to
obtain the desired adhesion between the pavement layers at a
significant loss of efficiency and increase in cost. Furthermore,
where the coatings are tracked to other surfaces by vehicles,
extensive cleanup may be required adding to the expense of a
project.
[0020] The use of conventional asphalts for tack coats, in
addition, often requires equipment adapted to maintain those
products at an elevated temperature throughout the application
procedure. Such equipment is often expensive to operate and
difficult to maintain, which increases the cost and reduces the
efficiency of the asphalt tack coats. Also as it relates to cutback
asphalt products specifically, they contain volatile solvents that
can damage the environment and are released into the atmosphere
during the curing process. These volatile solvents in asphalt
cutbacks further present safety issues during their storage and
application. As a result, cutback asphalt products are, or could
become, prohibited from general usage in many states.
[0021] Coal tar products made with the addition of various solvents
may also be used as a bond coating between pavement layers.
However, there are also many concerns with these tar products, such
as the use of volatile and toxic solvents, carcinogenic concerns,
and relatively low melting points resulting in soft and tacky
surfaces creating similar environmental and tracking problems as
with the prior asphalt-containing coatings.
SUMMARY OF THE INVENTION
[0022] The present invention provides a method for supplying a
low-tracking, adhesive tack coat capable of bonding together layers
of a pavement structure at ambient conditions for pavement
construction, and, in one aspect at temperatures of about
140.degree. F. (60.degree. C.) to about 170.degree. F. (77.degree.
C.). In one aspect, the method comprises applying an asphalt
emulsion composition, at ambient conditions for pavement
construction, to a substrate to produce a tack coating with a pen
value(s) and a softening point(s) in the range of hard pen asphalt
compositions. In one such aspect, the low tracking property of the
tack coat is provided by a pen value of about 40 dmm or less and a
softening point greater than about 140.degree. F. (60.degree. C.).
The emulsion may be applied as a coating, spray, or other suitable
delivery form in an amount sufficient to provide an effective tack
coat.
[0023] The tack coat of the invention provides a durable low tack
surface capable of resisting damage from vehicle traffic or other
sources. The tack coat of the invention further softens, and may
partially liquefy, when contacted by heated paving materials as
such paving materials are applied to the coating and substrate. At
these elevated temperatures, the tack coating is sufficiently
adhesive to bond asphalt-containing or other pavement layers
together in a pavement structure. The bond between the pavement
layers may increase in strength as the structure cools below the
softening point of the tack coat, and the tack coat rehardens. In
one aspect, the bond between the tack coat produced by the method
of the invention is significantly stronger than the bond provided
by conventional tack coats.
[0024] In another aspect, the method may be used for bonding
asphaltic pavement layers to a base or sub-base for a pavement
structure in the construction of new pavement structures or may be
used in rebuilding or restoring existing pavement structures. In
this aspect, the method comprises providing an amount of the
emulsion composition for forming the hard pen tack coat between at
least one asphaltic pavement layer and a second pavement layer in
an amount effective to form an adhesive interface between the
layers upon heating of the hard pen coating by at least one of the
pavement layers to a temperature sufficient to soften the hard pen
coating.
[0025] In yet another aspect, the emulsion comprises at least a
first phase of a hard pen asphalt composition and a second phase of
water. The emulsion may contain emulsifiers, stabilizers, and/or
additives to effectively emulsify and maintain the hard pen asphalt
composition phase in a substantially emulsified form. In another
aspect, the emulsion comprises at least a first phase of either a
mid to soft pen asphalt and a second phase of water, with
polymeric, waxes, or other additives sufficient to decrease the pen
value and increase the softening point of the applied tack coat to
the range of hard pen asphalt compositions, as well as emulsifiers,
and/or stabilizers to effectively form and maintain the
emulsion.
[0026] In this aspect of the method, the emulsion is applied as a
coating, spray, or other suitable delivery form. The asphalt
components and any polymeric or other equivalent additives are
selected to provide a low tack surface at typical ambient condition
for pavement construction, and an adhesive surface at temperatures
exceeding about 170.degree. F. (76.degree. C.), such as those of
newly applied asphaltic pavement layers.
[0027] In another aspect of the invention, the asphalt compositions
used to form the asphalt phase of the emulsion are selected from
hard pen asphalts to provide an effective tack coat that cures
after application to a durable surface capable of accepting vehicle
traffic without significant tracking or damage to the coating
relative to prior conventional tack coats. In this aspect, the
cured coating further provides sufficient adhesion between the
pavement layers when heated by the application of heated pavement
materials and then cooled after the pavement materials are
compacted to prevent substantial slippage or shifting of the
applied pavement materials due to traffic, environmental
conditions, or other adverse conditions.
[0028] In yet another aspect, the asphalt composition of the first
asphalt phase of the emulsion is selected from mid to soft pen
asphalts, and the water phase incorporates polymeric, wax, or other
equivalent additives that act with the asphalt composition to
provide a hard pen tack coat. In this aspect, the polymer or other
additives are selected to also provide a tack coat softening point
effective to bond pavement layers at the applicable paving
temperatures.
[0029] In one aspect of the method, the composition of the
emulsion, the emulsion application rate, and the amount of applied
emulsion is effective to form a tack coat that adheres and/or fuse
asphaltic material to a roadway base or substrate. In this aspect,
the asphalt composition of the asphalt phase and any additives are
selected so that the emulsion cures to provide a low tack surface,
typically in about 10 minutes to one hour, depending on weather
conditions (i.e., surface temperature, wind, humidity, exposure to
direct sunlight, etc.).
[0030] In yet another aspect of the method, the first phase of the
emulsion comprises from about 30% to about 70% of a hard pen
asphalt (or equivalent composition) based on the total weight of
the emulsion. In one such aspect, the hard pen asphalt composition
selected for use in the emulsion have pen values of about 5 dmm to
about 15 dmm and a softening point between 150.degree. F.
(66.degree. C.) and 160.degree. F. (71.degree. C.). The emulsion
also comprises a second phase of water which provides from about
30% to about 70% of the total weight of the emulsion, as well as
emulsifiers, stabilizers, and/or other additives in amounts of
about 0.1% to about 3% of the total weight of the emulsion.
[0031] In an alternative aspect, the first phase emulsion comprises
from about 30% to about 70% of asphalt compositions with pen values
greater than about 40 dmm and softening points less than about
140.degree. F. (60.degree. C.). The asphalt phase and/or water
phase further are provided with up to about 30% by weight of
polymeric, waxes, or other additives in amounts sufficient to form
a cured tack coat from the emulsion with pen values below 40 dmm
and softening points above about 140.degree. F. (60.degree. C.). In
this aspect, the balance of the emulsion comprises from about 30%
to about 70% by weight water, with from 0.1% to about 3%
emulsifiers, stabilizers and other additives.
[0032] In one aspect, the emulsion is applied at a rate of from
about 0.01 to about 0.20 gal/sq. yd., (0.045 liters/sq. meter to
0.90 liters/sq. meter) and in another aspect from about 0.04 to
about 0.08 gal/sq. yd (0.18 liters/sq. meter to 0.36 liters/sq.
meter). In yet another aspect, the emulsion can be applied in
multiple passes over the substrate layers at lower rates to achieve
a comparable product, where the total application rate is equal to
the sum of the multiple passes and is from about 0.01 to about 0.20
gal/sq. yd., (0.045 liters/sq. meter to 0.90 liters/sq. meter). The
substrate layers may include soil, clay, sand, shell, cement,
limestone, fly ash or mixtures thereof, and, in another aspect, the
layers would comprise hot mix asphalt layers, a preexisting paving
surface, or a scraped, ground, or scored paving surface.
[0033] In another aspect, the method produces a low-tracking tack
coat that may be applied relatively easily to an existing substrate
surface, which is both very effective and cost efficient. In one
aspect, the tack coating dries relatively quickly, in about 5 to
about 15 minutes, and in another aspect the tack coating cures in
about 30 minutes to one hour, and resists cracking and separation
from the existing base course. The properly cured base coat is
resistant to damage by vehicle tires due to tracking and pick up of
the coating on the vehicle tires and tracks. Thus, the method
permits a delay of hours, days, or even weeks between application
of the tack coating and of the application of the second pavement
layer.
[0034] In yet another respect, when a heated pavement layer is laid
down on the tack coat, heat from the pavement softens, and may
re-liquefy, the asphalt composition of the coating, which becomes
tacky and bonds or fuses the two layers together. This aspect of
the method does not require the use of heated application
appliances for the coating or the use of large quantities of energy
to maintain the coating at elevated temperatures during treatment
of the base or prepared pavement.
[0035] In another aspect, emulsifying and/or stabilizing additives
may be selected such that the emulsion of the method can be
prepared at temperature conditions that are typically used for
making soft and moderate penetration asphalt emulsions. Due to the
addition of such emulsifying agents and stabilizers, the hard pen
asphalt emulsion can be produced at conventional temperatures and
remains stable during storage.
[0036] In another aspect of the invention, a pavement structure is
provided comprising a first substrate layer, and one or more
additional layers of asphaltic or equivalent pavement materials,
having the hard pen tack coat disposed there between. In another
such aspect, additional pavement layers are added to the first
pavement layer with the hard pen tack coat of the invention there
between. In yet another aspect, the bond strength between the
substrate and first pavement layer, and between each subsequent
paving layer, is greater than the bond strength between the
substrate and first layer, and between each subsequent layer, of
the pavement structure formed with conventional tack coats.
[0037] The method of the invention provides good adhesive strength
and bond strength between each layer of the pavement structure, so
that the surfaces of each layer resist slipping or sliding relative
to one another. The method allows scheduling flexibility in laying
down the new pavement layer, such that additional pavement layers
may be applied at a later date after the emulsion is cured.
[0038] The use of the method for pavement maintenance and/or
rejuvenation increases the economic life of the pavement structure
and, in some aspects, provides a better density at the pavement
joints and throughout the pavement. Similarly, the method
substantially eliminates the need for large volumes of cutback or
other products with significant amounts of solvents and thinners
that endanger the environment or surrounding personnel when they
are released during the curing process. In one aspect of the
invention, an analysis of the polycyclic aromatic hydrocarbons
released by the tack coat of the invention were significantly
reduced relative to other, particularly cutback, tack coat
products, and in some instances were virtually undetectable.
DETAILED DESCRIPTION
[0039] One aspect of the method of the invention comprises the
application of an emulsion of a hard pen asphalt material, or an
equivalent as discussed herein, to an existing base or substrate
for a pavement structure to provide a hard pen, low-tracking,
adhesive tack coat between the existing substrate base and a new
asphaltic pavement layer. In another aspect, the method provides
for applying the tack coat significantly in advance of the
application of the new substrate layer and, in some aspects, the
method provides for application of the tack coat from hours to
months in advance of the application of the new pavement layer. The
base or substrate layers may include soil, clay, sand, shell,
cement, limestone, fly ash or mixtures thereof, as well as
asphaltic materials and prepared preexisting surfaces of pavement
structures.
[0040] In one aspect of the method, the emulsion is prepared from
an asphalt composition, water, emulsifiers, stabilizers, and/or
other additives. In this aspect, the pen value of the asphalt
composition component is less than about 40 dmm pen and possesses a
softening point greater than about 140.degree. F. (60.degree. C.).
In another aspect, the pen value of the asphalt composition
component is from about 5 dmm to about 15 dmm pen, with a softening
point between about 150.degree. F. (66.degree. C.) and about
160.degree. F. (71.degree. C.).
[0041] The emulsion may comprise at least a first asphalt phase and
a second phase of water, as well as emulsifying agents, and/or
stabilizing additives. The emulsion optionally may further include
additives providing an anionic, cationic or neutral character to
the final emulsion. The pen value or range of values of the asphalt
composition providing the first asphalt phase, and the emulsifiers,
stabilizers, and additives are selected so that the asphalt
composition may be combined with the water phase at temperatures
and under mixing conditions that produce a successful emulsion.
[0042] In one aspect, the emulsifier package includes emulsifiers
suitable for use with hard pen asphalt having pen values under 40
dmm such as that available from Echo Star Science Technologies,
Sacramento, Calif. The emulsifiers and/or stabilizers maintain the
asphalt material in a stable suspension and control the breaking
time, where the breaking time is the rate at which asphalt
materials separate from the water phase permitting the evaporation
of the water and forming the cured or set tack coating. The
emulsifiers also may include surfactants, acid/base materials, etc.
The stabilizers may include polycarboxylate polymers,
preservatives, etc.
[0043] Other additives may include, but are not limited to, common
polymers such as EVA, SBS, SB, SBR, SBR latex, waxes,
polychloroprene, isoprene, polybutadiene, acrylic and acrylic
copolymers, carbon reinforced elastomers, ground tire rubber,
and/or other elastomers and plastomers to assist in obtaining
desired breaking rates for the emulsion and adhesion of the asphalt
emulsion residue. Long term stabilizers and/or other additives that
are beneficial for a particular application also may be
incorporated in the emulsion.
[0044] In preparing the emulsion, the asphalt composition component
is mixed with water, emulsifiers, stabilizers and any other
additives through a high-speed, high shear mechanical mixer, such
as a colloid mill, or other equipment capable of emulsifying the
concentrate constituents. The asphalt composition component, water,
emulsifiers, stabilizers, and other additives typically are heated
to assist in the dispersion of the asphalt composition. In one
aspect, the temperature of the finished emulsion is maintained
below about 212.degree. F. (100.degree. C.), and preferably from
about 160.degree. F. (71.degree. C.) to 210.degree. F. (99.degree.
C.). The use of such temperatures avoids boiling of the water phase
which interferes with the emulsification process.
[0045] In the above aspect of the emulsion, the contemplated weight
percentage of the asphalt composition component in at least the
first phase is from about 30% to about 70% of the total weight of
the emulsion (as used herein, all percentages are by weight). The
water phase of the emulsion, in this aspect, comprises from about
30% to about 70% of the total weight of the emulsion. The
emulsifiers, stabilizers, and/or other additives comprise from
about 0.1% to about 3.0% of the total emulsion weight, and
preferably from about 0.5% to about 3.0% of the total emulsion
weight.
[0046] In an alternative form of the emulsion, the pen value of the
asphalt composition is greater than about 40 dmm pen and possesses
a softening point less than about 140.degree. F. (60.degree. C.),
and may be in the range of mid or soft pen asphalt compositions (or
mixtures thereof). In this form, the emulsion contains polymeric,
waxes, or other equivalent additives that provide a final cured
tack coat with a pen value(s) less than about 40 dmm pen and a
softening point(s) greater than about 140.degree. F. (60.degree.
C.). Examples of such polymeric additives are EVA, SBS, SB, SBR,
SBR latex, polychloroprene, isoprene, polybutadiene, acrylic and
acrylic copolymers, and other equivalent additives that produce the
hard pen characteristics of the final cured tack coat.
[0047] This form of the emulsion also includes emulsifiers and
stabilizers, and may include other additives to provide the desired
handling and breaking characteristics. The polymeric additives,
equivalents thereof, emulsifiers, stabilizers, and/or other
additives in this form of the emulsion comprise about 0.1% to about
30.0% of the total weight of the emulsion.
[0048] In the form of the emulsion using mid to soft pen asphalt
compositions, the above mentioned polymeric additives may be added
to the first phase comprising the mid to soft pen asphalt, or
alternatively the polymers may be added to the second water phase
of the emulsion. The contemplated weight percentages of the asphalt
composition component may comprise from about 30% to about 70% of
the total weight of the emulsion and the water phase of the
emulsion comprises from about 30% to about 70% of the total weight
of the emulsion.
[0049] In one aspect of the method, the final emulsion is prepared
by mixing a concentrate emulsion containing the first asphalt
composition component, the emulsifiers, stabilizers and any other
additives and water. In this aspect, sufficient water is added to
the concentrate to provide the desired asphalt composition and/or
additive content in the final emulsion. In one example of this
approach, the concentrate is provided with an asphalt composition
component comprising about 36% to about 70% of the total weight of
the emulsion. The water phase of the emulsion, in this aspect,
comprises from about 30% to about 64% of the total weight of the
emulsion. The emulsifiers, stabilizers, and/or other additives
comprise from about 0.1% to about 3.0% of the total emulsion.
[0050] The final emulsion using the concentrate comprising about
36% to about 70% asphalt composition may be mixed with an amount of
water to provide 100 parts concentrate to 20 parts water. In such a
final emulsion, the asphalt composition component comprises about
30% to about 58% by weight of the final emulsion. The water
component comprises about 70% to about 42% of the final emulsion.
In such an emulsion, the ratio of the hard pen asphalt composition
to water in the final emulsion is from about 1:2.33 to about 1:0.7.
In another example, the asphalt composition component comprises
about 65% of the concentrate and sufficient water is added to
provide a final emulsion comprised of about 32% to about 55% of the
asphalt composition component.
[0051] As discussed above, the final emulsion having such ratios of
hard pen asphalt to water also may be prepared directly from the
constituents, rather than from a concentrate. The emulsion should
remain stable during storage and typically may be stored for about
14 days, depending on the constituents. Some settling may occur,
but a light (simple) agitation of the emulsion usually re-disperses
asphalt into the concentrate.
[0052] The specific ratio of the first hard pen asphalt phase to
the second water phase in the final emulsion chosen for a
particular application will depend on factors such as the
composition of the preexisting pavement or the base course
materials and conditions, the number of planned applications; the
desired cure time, and user agency regulations and/or
specifications. Similarly, the emulsifiers, stabilizers, and other
additives may be adjusted for specific application conditions,
asphaltic materials, and substrates.
[0053] As mentioned above, the final emulsion is formulated such
that, after proper application, the final coating possesses a
maximum penetration of about 40 dmm and a minimum softening point
of about 140.degree. F. (60.degree. C.) and in some aspects, from
about 5 dmm to about 20 dmm with a softening point of about
150.degree. F. (66.degree. C.) to about 160.degree. F. (71.degree.
C.). The asphalt composition grades used in the emulsion may be
further defined by the upper end values of the Performance Grade
(PG) values of the Strategic Highway Research Program (SHRP).
[0054] The asphalt composition grades may comprise about PG-91
upper end value (about 5 pen) to about PG-82 upper end value (an
upper end value of about 40 pen) or their equivalents, and/or
combinations thereof, and in some aspects from a PG-91 upper end
value to a PG-85 (about 20 pen) upper end value. The asphalt
composition component typically includes mixtures of asphalt
(asphaltenes, maltenes and/or mixtures of other asphaltic
components), residual emulsifier(s), and/or additives that would
provide properties similar to asphalt grades possessing a
penetration value under 40 dmm and a softening point greater than
140.degree. F. (60.degree. C.).
[0055] The properties of one aspect of the emulsion of the
invention are as follows in the chart below describing the
properties of the final emulsion and the hard pen asphalt tack
coat. The test protocols are those described by the referenced
standards published by ASTM, International ("ASTM"); the American
Association of State Highway and Transportation Officials
("AASHTO"), and the Federal Highway Administration ("FHWA"). The
examples provided below are only for illustrative purposes, and
alternative formulations also may be used in the method of the
inventions:
TABLE-US-00001 Property Test Minimum Maximum EMULSION PROPERTIES
Saybolt Furol ASTM D88 About 25 -- Viscosity Seconds @ 77.degree.
F. (25.degree. C.) Storage Stability, 24 ASTM D244 -- About 1
hours, % by mass Storage Stability, 5 ASTM D244 -- About 5 days, %
by mass Residue by ASTM D86 About 30 -- Evaporation, % by mass
Naphtha Content, % ASTM D86 -- About 1 by mass Sieve Test, % by --
About 0.15 mass Fuel Resistance ASTM D3370 PASS TACK COAT
PROPERTIES Penetration, 77.degree. F. ASTM D5 About 1 About 40
(25.degree. C.), 100 g, 5 sec. dmm R&B Softening ASTM D36
140.degree. F. (60.degree. C.) -- Point Range Residue by ASTM D86
About 30 -- Distillation % by mass Original Binder AASHTO T315 1 --
DSR; G*/Sind @ 180.degree. F. (82.degree. C.)
[0056] As previously discussed, the final emulsion may be prepared
in advance of its application or at a work site immediately before
its application. In another aspect, it is possible to mix the
concentrate with water at a rate sufficient to produce the desired
final emulsion on a continuous basis during the application step
using metering and mixing equipment known to those skilled in the
art.
[0057] In the application step of the method, the hard pen asphalt
final emulsion may be applied by hand spreading in one aspect, and
in other aspects using conventional spreading or spraying
equipment, or other comparable equipment. In one aspect, an
effective amount of the emulsion may be obtained at a rate of about
0.01 to about 0.20 gal/sq. yd., (about 0.045 to 0.90 liters/sq.
meter), and in one case an application rate of about 0.04 to about
0.08 gal/sq. yd. (about 0.18 to 0.36 liters/sq. meter) also may be
used. In yet another aspect, the emulsion can be applied in
multiple passes over the substrate layers at lower rates to achieve
a comparable product, where the total application rate is equal to
the sum of the multiple passes and is from about 0.01 to about 0.20
gal/sq. yd., (0.045 liters/sq. meter to 0.90 liters/sq. meter). For
example, an emulsion may be applied in three passes over the
substrate layer at application rates of about 0.01 gal/sq. yd.
each, or a total application rate of about 0.03 gal/sq. yd. The
rate of application of the emulsion may vary depending on the
specified application conditions, composition of the emulsion, the
surface to which it is applied, and the nature of the permanent
materials and/or base that comprise the pavement structure, and
other similar factors.
[0058] In one aspect, the temperature during application of the
hard pen emulsion is from about 140.degree. F. (60.degree. C.) to
about 180.degree. F. (82.degree. C.), and in another aspect from
about 165.degree. F. (74.degree. C.) to about 175.degree. F.
(80.degree. C.). Alternatively, the emulsion coat may be applied at
ambient temperature (e.g. about 68.degree. F. to 77.degree. F.
(about 20.degree. C. to 25.degree. C.)), which may affect the
curing time of the emulsion. The emulsion typically is placed
directly on top of the exposed surface of the existing prepared
surface or base course and is allowed to cure before traffic passes
over the coated surface or an additional layer of pavement is
applied to the treated surface.
[0059] The applied hard pen final emulsion typically cures in about
15 minutes to about 45 minutes, and may cure as rapidly as about 5
to about 15 minutes after the emulsion is applied to the exposed
surface of the prepared surface or base course. The cure rate will
depend on the application rate, the dilution ratios used, the base
course conditions, the weather, and other similar considerations.
If the prepared pavement surface or base course contains excess
moisture, the curing time of the emulsion may be increased.
[0060] After the tack coating is cured, traffic may be permitted to
pass over the roadway or paving materials may then be applied to
the base course. The hard pen tack coating creates a durable, low
tack (and in some instances no tack) surface, and as such it
restricts tracking to other surfaces via vehicle tires or
treads.
[0061] In another aspect of the method, a layer of pavement
materials is applied to the tack coated surface after the hard pen
asphalt emulsion has cured. The pavement materials suitable for use
in this aspect of the method are applied at elevated temperatures
sufficient to heat the exposed surface of the coating to a
temperature greater than about 140.degree. F. (60.degree. C.) when
the pavement materials are applied to the coated substrate surface.
In one example, conventional hot mix asphalt paving materials are
applied at elevated temperatures such as about 212.degree. F.
(100.degree. C.) to 350.degree. F. (177.degree. C.), and, also may
be in excess of about 280.degree. F. (138.degree. C.). After the
paving materials are applied, they are compacted or otherwise
pressed in place in preparation for the next paving course or
finishing of the traffic bearing surface of the structure.
[0062] Without being limited to one theory for the success of the
invention, at such temperatures, it is believed that the layer of
heated paving materials softens, and in some aspects, liquefies the
hard pen tack coat to form an adhesive interface between the
pavement layer and substrate (or between pavement layers) to bind
and/or fuse the pavement layer and substrate together when the tack
coat rehardens, normally by cooling. When the new pavement layer
cools and hardens, as discussed above, the hard pen asphalt residue
layer also cools and hardens to form an effective bond between the
layers.
[0063] It also is believed that when compaction occurs, the
pavement and/or base layers may become interlocked with the tack
coat. Thus, the complete pavement structure or substructure is
provided with a strong bond which inhibits, and in some aspects
prevents, the movement or separation of the pavement layers.
[0064] Thus, the method of the invention provides a multi-layer
pavement structure with hard pen asphaltic tack coat/binder between
each layer. As also discussed below, the bonding between layers of
such structures can be superior to paving structures made using
conventional tack coats and cutback asphalt tack coats. The
structure provided by the method of the invention may include a
substrate and one or more asphalt or other paving layers with a
tack coat between the substrate and first paving layer, and between
subsequent layers. The structure of the invention also may comprise
multiple layers of new or existing paving surfaces, with the tack
coat therebetween. It may include an existing paving surface that
is treated, grooved or otherwise prepared to receive one or more
layers of paving materials.
[0065] In view of the air pollution/quality issues of concern with
conventional emulsion and cut-back products, the undesirable
polycyclic aromatic hydrocarbon (PAH) levels produced by one
example of an asphalt composition component used in the emulsion of
the invention was measured, which provides an estimate of the PAH
levels produced by the set or cured emulsion after application to a
suitable surface. The measurements were made of a grade of asphalt
with a penetration value of about 20 dmm. The tests were conducted
by DHL Analytical, Round Rock, Tex., using a method referenced as
Method SW8270C.
[0066] The PAH's from this sample were undetectable under those
criterion for 16 of the 19 of the tested PAH's and were well within
the acceptable levels for the remaining three PAH's
(2-Fluorobiphenyl, 81.9; 4-Terphyl-d14, 66.1; and Nitrobenzene-d5,
80.0; where the acceptable range was 40-140). These results were
superior to conventional tack coat emulsion and cutback products.
The PAH levels, of course, will depend on the specific composition
of the emulsion used to form the tack coat.
EXAMPLES
[0067] One example of the method was used to form a tack coat by
applying the emulsion of the invention using a 13 dmm pen asphalt,
comprising about 33% by weight of the emulsion. The emulsion was
applied at a rate of 0.03 gal/sq. yd. (0.135 liters/sq. meter) to a
first layer of asphaltic pavement material and was covered by a
second layer of asphaltic pavement material. The asphalt emulsion
sample was identified as TT (Trackless tack).
[0068] A conventional MS (medium set) emulsion also was applied at
the same rate to the first asphaltic layer and covered by the
second layer of asphaltic materials. The MS emulsion contained a
minimum 50 dmm pen asphalt that comprised at least about 62% of the
emulsion. Core samples were taken from each portion of the pavement
structure and tested for the shear force required to separate the
layers apart, and the bond strength between layers was calculated.
The test results for both types of tack coats are listed below:
TABLE-US-00002 TABLE 1 Core Shear Force to Bond Diameter Area
Separate Layers Strength Sample (in) (in.sup.2) (lbs) (psi) Tack
Coat Formed By Medium Set (MS) Emulsion MS-1 5.95 27.81 1440 51.8
MS-2 5.94 27.69 1920 69.3 MS-3 5.95 27.84 2080 74.7 MS-4 5.95 27.81
1840 66.2 MS-5 5.95 27.81 2020 72.6 MS-6 5.96 27.85 3070 110.2 MS-7
5.95 27.81 2540 91.4 Average 5.95 27.80 2130 76.6 Tack Coat Formed
By Improved Method TT-1 5.94 27.75 2790 100.5 TT-2 5.95 27.81 2360
84.9 TT-3 5.95 27.79 2200 79.2 TT-4 5.95 27.81 1800 64.7 TT-5 5.95
27.81 2300 82.7 TT-6 5.95 27.81 2980 107.2 TT-7 5.95 27.78 2020
72.7 Average 5.95 27.79 2350 84.6
[0069] Accordingly, Table 1 represents a relative comparison of the
two tack coats based on using the same asphalt conditions for
application of the emulsions. Different results may be obtained
when different asphalts and/or conditions are used, however, the
general relative outcome for the two types of methods should be
very similar.
[0070] In another example, the method of the invention was used to
form a tack coat by applying the emulsion of the invention using a
13 dmm pen asphalt, comprising about 37% by weight of the emulsion.
The emulsion was applied at a rate of 0.03 gal/sq. yd. (0.135
liters/sq. meter) to a first layer of an asphaltic pavement
material and was covered by a second layer of asphaltic pavement
material.
[0071] A conventional RS (rapid set) emulsion also was applied to
the first asphaltic layer at the same rate and covered by the
second pavement layer. The asphalt in the RS emulsion was a minimum
of about 60 dmm pen comprising at least about 62% of the emulsion.
The bond created by the RS emulsion between the layers also was
tested. Core samples were taken from the pavement structure after
the passage of similar curing times and tested for the force
required to shear the layers apart, and the bond strength between
layers was calculated. The test results for both types of tack
coats is listed below:
TABLE-US-00003 TABLE 2 Interface Tack Type Core ID PSI Condition RS
1-1 70 Wet 1-2 121 Damp 1-3 116 Damp 1-4 87 Wet 1-5 105 Wet 1-6 95
Wet Tack Coat Formed 2-1 61 Wet By Improved 2-2 188 Dry Method 2-3
178 Dry 2-4 178 Dry 2-5 161 Dry 2-6 150 Dry Tack Type PSI Average
RS 99 (Section 1) Improved Method 153 Difference 54 between
Types
[0072] Accordingly, this data confirms the increased bonding and
curing time produced by the method of the invention.
[0073] While the invention has been described by reference to
certain specific descriptive examples which illustrate preferred
materials and conditions, it is understood that the invention is
not limited thereto. Rather, the invention includes all
alternatives, modifications and equivalents within the scope of
this disclosure.
* * * * *