AAPA Guide To The Handling Storage Manufacture of PMB's Final Version Jan 2013 PDF
This document provides guidelines for the manufacture, storage, transport, handling and application of polymer modified binders (PMBs). It outlines best practices to ensure consistent quality of PMBs and reduce potential degradation. The document covers PMB manufacturing processes and equipment, sampling and testing procedures, transport and storage requirements, and application of PMBs in asphalt and sprayed sealing work. It aims to promote high quality PMBs through coordinated control across the manufacturing and usage process.
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AAPA Guide To The Handling Storage Manufacture of PMB's Final Version Jan 2013 PDF
This document provides guidelines for the manufacture, storage, transport, handling and application of polymer modified binders (PMBs). It outlines best practices to ensure consistent quality of PMBs and reduce potential degradation. The document covers PMB manufacturing processes and equipment, sampling and testing procedures, transport and storage requirements, and application of PMBs in asphalt and sprayed sealing work. It aims to promote high quality PMBs through coordinated control across the manufacturing and usage process.
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GUIDE TO THE MANUFACTURE, STORAGE AND
HANDLING OF POLYMER MODIFIED BINDERS
Disclaimer Although the information contained in this booklet is believed to be fundamentally correct and current at time of printing, the Australian Asphalt Pavement Association does not accept any contractual, tortious or other form of liability for its contents or any consequences arising from its use. GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS Foreword The Australian Asphalt Pavement Association (AAPA) has prepared this guide as an aid to promoting best practice in the manufacture, storage, transport, handling and application of polymer modied binders. This document replaces the previous version entitled Code of Practice: Manufacture, Storage and Handling of Polymer Modied Binders, which was published in June 2004. A signicant difference between Polymer Modied Binders (PMBs) and conventional bitumen is the need for additional care in handling to ensure that the effectiveness of the polymer or rubber crumb is not reduced by overheating, contamination, or other degradation during storage and transport. Procedures contained in this guide are intended to provide assurance to end users of consistent quality of hot PMB materials produced in a controlled manufacturing environment. Issues relating specically to the production of PMBs by the addition of either polymer or rubber crumb in the eld (i.e. at the point of use) will be covered in a separate guide. Specic requirements for PMB emulsions are also excluded from this guide as these materials require different storage and handling practises. Acknowledgements AAPA wishes to acknowledge the contributions of the following individuals and groups: Technical Writer of Original Draft John Rebbechi Roadcor Pty Ltd Document Review Working Group Stuart Dack BP Bitumen Trevor Distin Boral Asphalt Nigel Preston Shell Review Groups: AAPA Binder Producers Group John Arvanitidis Caltex Robert Busuttil AAPA Warren Carter Downer Australia Stuart Dack BP Bitumen Trevor Distin Boral Asphalt Gerard Gnanseelan SAMI Bitumen John Lysenko Fulton Hogan Sam Maccarrone ExxonMobil Neil Morcombe Bituminous Products Nigel Preston Shell Austroads Asphalt Research Working Group (ARWG) Austroads Bituminous Surfacings Working Group (BSWG) GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS Contents 1. INTRODUCTION 1 2. MANUFACTURE 1 2.1 General 1 2.2 Equipment 1 2.3 Manufacturing process 2 2.3.1 Overview 2 2.3.2 Bitumen supply and storage 2 2.3.3 Combining agent 2 2.3.4 Polymer 2 2.3.5 Pre-blending 2 2.3.6 Mixing 2 2.3.7 Storage of nished product 3 2.3.8 Testing and release of product 3 2.3.9 Loading gantry 3 2.4 Product testing and evaluation 3 2.5 Temperature 3 2.6 Non-conforming products 3 3 SAMPLING AND TESTING 4 3.1 Sampling 4 3.2 Laboratory Testing 4 3.3 Tracing Properties of Delivered Materials 5 3.4 Material Safety Data Sheet (MSDS) 6 4 TRANSPORT, STORAGE AND APPLICATION 6 OF PMBs 4.1 General handling and safety requirements 6 4.2 Special requirements for PMBs 6 4.2.1 Temperature 6 4.2.2 Moisture 6 4.2.3 Cleaning materials 6 4.2.4 Segregation 6 4.2.5 Loading of delivery vehicles 7 4.2.6 Reheating during transport 7 4.2.7 Delivery into storage tanks or 8 bitumen sprayers 4.2.8 Field sampling 8 5 ASPHALT WORK 9 5.1 General 9 5.2 Production of asphalt mixes 9 5.3 Placement and Compaction 9 6 SPRAYED SEALING WORK 9 6.1 General 9 6.2 Field procedures 9 6.2.1 General handling requirements for PMBs 9 6.2.2 Cutter 10 6.2.3 Adhesion Agent 10 6.2.4 Aggregate Precoating 10 REFERENCES 11 GLOSSARY 12 Australian Asphalt Pavement Association Limited (AAPA) AAPA is a non-profit organisation formed to promote the economic use of asphalt based on sound technical grounds. The Associations Mission Statement for Research and Development is to ensure the attainment of the optimum level of quality and long-term performance in flexible pavement design, construction and maintenance. The AAPA Technology Committee manages the AAPA R&D Program for Asphalt Research and Technology and works in close cooperation with the Austroads Pavement Reference Group. The research programs are coordinated and complementary. Reproduction of extracts from this publication may be made subject to due acknowledgement of the source. GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS 1 1. INTRODUCTION This guide to best practice has been prepared by the manufacturers and users of Polymer Modied Binders (PMBs) to: Provide guidelines for the manufacture and handling of hot PMBs. Provide assurance to end users of the consistent manufacturing quality of delivered products. Reduce the potential for degradation and contamination due to inappropriate handling or heating during the delivery, storage and application processes. PMBs generally consist of a blend of paving grade bitumen and polymer or rubber crumbs. In some cases, combining agents and other additives are added to the base bitumen to assist in blending and achievement of particular performance characteristics. The normal safety, quality and environmental considerations involved in the manufacture, storage and handling of a PMB includes: Accurate blending of materials and control of manufacture to ensure that the product conforms to the required specication. Monitoring and control of temperature at all phases of manufacture, storage, transport and eld use to avoid premature deterioration of polymers or rubber crumbs at high temperatures. Maintenance of the homogeneity of some mixtures that may segregate. Avoidance of contamination with other products that may alter performance characteristics of the product. A number of different organisations may be involved in the manufacture, sampling and testing, transport and application of PMBs. Control throughout the process needs to be coordinated and responsibility accepted by the various organisations. This guide is intended to be complementary to the following publications: AAPA HS&E Guide No. 5: Guide to the safe use of SBS Austroads Bituminous Materials Safety Guide, AP-G41/08 Austroads Specication Framework for Polymer Modied Binders and Multigrade Bitumens, AG:PT/T190 Austroads Guide to the Selection and Use of Polymer Modied Binders and Multigrade Bitumens, AP-T42/06 Austroads Modied Binder Test Methods ( http://www.austroads.com.au/pavements ) AAPA Advisory Note 7: Guide to the Heating and Storage of Binders for Sprayed Sealing and Hot Mixed Asphalt Australian Dangerous Goods Code, 7th Edition (October 2011). Other relevant publications are referenced at the end of this document, including Austroads guides, Technical Reports and Pavement Work Tips. 2. MANUFACTURE 2.1 General The manufacturer should establish, document and maintain a quality system to ensure that the products supplied conform to the stated specications. The quality system should consist of procedures, regular inspections and tests and/or assessments and the use of the results to control the quality of the nished product. A quality system conforming to the requirements of ISO 9001 and made specic to the requirements of the Austroads Specication Framework for Polymer Modied Binders and Multigrade Bitumens and the AAPA Guide to the safe use of SBS, is considered to satisfy the above requirements. The results of inspections, tests or assessments requiring action should be recorded, as should any action taken. The action to be taken when control values or criteria are not met should be recorded and retained for the period specied in the manufacturers quality procedures. 2.2 Equipment Testing - all laboratory weighing, measuring and testing equipment should be calibrated and regularly inspected according to documented procedures, frequencies and criteria. Manufacturing - all equipment used in the manufacturing process should be regularly inspected, calibrated and maintained to ensure use, wear or failure does not cause inconsistency in the manufacturing process. Inspections and maintenance should be carried out and recorded in accordance with the manufacturers written procedures, and the records retained for the period dened in the manufacturers quality procedures. GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS 2 2.3 Manufacturing process 2.3.1 Overview A general ow diagram for the process of PMB manufacture using a high shear mill is shown in Figure 1. Further notes on the requirements for each element of the manufacturing process are described in the following sections. Figure 1: Manufacturing process 2.3.2 Bitumen supply and storage The consistency and quality of the base bitumen used for PMB manufacture should be monitored, for example, through the use of suppliers certicates of compliance, to ensure appropriateness for PMB manufacture. Similarly, bitumen in storage should be monitored to ensure no adverse changes occur that may adversely impact PMB quality. Systems should identify procedures for assessing the inuence of changes in source of bitumen materials on the required proportions of other component materials and/or properties of the manufactured PMB. 2.3.3 Combining agent Combining agents are sometimes added to PMBs to improve their performance properties and shelf life and should comply with the requirements of the AAPA Guide to the safe use of SBS. Acceptance criteria and storage conditions for combining agents should be documented. Most PMBs are sufciently stable at normal processing and application temperatures. However, the inclusion of combining agents and other additives, coupled with higher temperatures than normally used with conventional bitumen, can produce a noticeable increase in fuming. It is the responsibility of the manufacturer to exclude the use of ingredients that have known adverse health effects and to ensure that all relevant safety precautions are followed, as set out in the suppliers Material Safety Data Sheet (MSDS). 2.3.4 Polymer The common generic polymer types used for the manufacture of PMBs specied in the Austroads Framework for Polymer Modied Binders and Multigrade Bitumens are Styrene Butadiene Styrene (SBS), Polybutadiene (PBD) and Ethylene Vinyl Acetate (EVA). These materials are generally proprietary products manufactured to strict quality standards. Experience has shown that a supplier certicate of compliance provides adequate verication of the quality of these materials. The characteristics of rubber crumbs used in the modication of bitumen are specied in Table 5.5 of the Austroads Specication Framework for Polymer Modied Binders and Multigrade Bitumens, AG:PT/T190. Incoming rubber crumb should be tested for compliance against these requirements. Every effort should be made to ensure that the rubber crumbs are free of moisture and foreign materials, such as steel and bre. Rubber crumbs should be stored in a manner that prevents exposure to rain and moisture. 2.3.5 Pre-blending Where raw materials are required to be pre-blended, procedures should be established and documented for proportioning, mixing and storing the blended material. 2.3.6 Mixing Component materials should be thoroughly mixed to ensure production of a homogeneous PMB. The design of mixing equipment varies considerably depending on the type of PMB being manufactured and can vary from high shear mills used to blend SBS pellets to low shear agitation for blending rubber crumbs. Critical elements that are common to all processes include procedures for proportioning of materials, temperature control, mixing time and conditions, and maintenance and cleanliness of equipment.
Polymer Modified Binders Guide 2 September 2012 made specific to the requirements of the Austroads Specification Framework for Polymer Modified Binders and Multigrade Bitumens and the AAPA Guide to the safe use of SBS, is considered to satisfy the above requirements.
The results of inspections, tests or assessments requiring action should be recorded, as should any action taken. The action to be taken when control values or criteria are not met should be recorded and retained for the period specified in the manufacturer's quality procedures.
2.2 Equipment Testing - all laboratory weighing, measuring and testing equipment should be calibrated and regularly inspected according to documented procedures, frequencies and criteria.
Manufacturing - all equipment used in the manufacturing process should be regularly inspected, calibrated and maintained to ensure use, wear or failure does not cause inconsistency in the manufacturing process.
Inspections and maintenance should be carried out and recorded in accordance with the manufacturer's written procedures, and the records retained for the period defined in the manufacturer's quality procedures.
2.3 Manufacturing process 2.3.1 Overview A general flow diagram for the process of PMB manufacture using a high shear mill is shown in Figure 1. Further notes on the requirements for each element of the manufacturing process are described in the following sections. Figure 1: Manufacturing process 2.3.2 Bitumen supply and storage The consistency and quality of the base bitumen used for PMB manufacture should be monitored, for example, through the use of supplier's certificates of compliance, to ensure appropriateness for PMB manufacture. Similarly, bitumen in storage should be monitored to ensure no adverse changes occur that may adversely impact PMB quality. Systems should identify procedures for assessing the influence of changes in source of bitumen materials on the required proportions of other component materials and/or properties of the manufactured PMB.
Bitumen tank Combining Agent tank Polymer Pre-blend tank Mill Finished product tank Loading Gantry GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS 3 2.3.7 Storage of nished product Tanks for the storage of nished product should be designed to minimise deterioration in storage, with strict control of temperature, minimal surface area to reduce oxidation, and provision for mixing or circulation to ensure that the product remains homogenous in storage. The heating system should be designed such that the PMB is not exposed to high contact temperatures around the heating elements or ues for prolonged periods. Prolonged exposure of PMBs to heating elements may result in deterioration and carbonisation of the binder. It is essential to provide good circulation of the PMB around heating elements or ues, either through the use of mechanical stirrers and/or by circulating the tank contents with a pump. A tank heating system commonly used for PMB storage uses heat transfer oil and automated temperature controls to limit overheating. While PMBs are generally manufactured for immediate delivery, any extended storage should be documented and monitored to ensure product conforms to the specied characteristics. 2.3.8 Testing and release of product Requirements for product testing and treatment of non- conforming product are outlined in Sections 2.4, 2.6 and 3.2. 2.3.9 Loading gantry All supply lines throughout the plant, including loading equipment, should be designed and procedures established so as to avoid contamination during change of product or cleaning of supply lines. The use of oils such as kerosene, diesel, or gas oil for ushing lines should be avoided. Where lines need to be ushed, it should be done with hot bitumen or nished product. Any oils used for ushing or cleaning of supply lines should be collected and disposed of separately and should not be added to products or components in storage or delivery vehicles. 2.4 Product testing and evaluation The manufacturer should establish procedures to ensure that conformance to the specied characteristics are maintained. The means of control are: a) By determining the appropriate PMB characteristics using the tests and test frequencies specied in the Austroads Specication Framework for Polymer Modied Binders and Multigrade Bitumens (AG:PT/T190); b) Routine control of product quality should be on a basis of checks, of a type and frequency to be dened and documented, to ensure that properties do not change signicantly from those specied. NOTES: 1. Where testing is required on each batch, a batch is considered to be the quantity of binder produced and stored in one tank once the production run into that tank has been completed. The batch can be considered to remain the same as long as no new production has been added. 2. The manufacturer should establish manufacturing targets for all test properties. Manufacturing targets may be different to specication limits. 2.5 Temperature The manufacturer should establish guidelines for the heating and storage of PMBs to avoid fuming or degradation of binders in the manufacturing process, supplier storage, transport, user storage and application. Guidelines should include the range of application temperatures, the maximum holding time at the maximum application temperature, the recommended storage temperature and the maximum time that materials may be held at the recommended storage temperature. A summary of manufacturers guidelines for heating and storage is published in AAPA Advisory Note 7 - Guide to the Heating and Storage of Binders for Sprayed Sealing and Hot Mixed Asphalt. Manufacturers should ensure that agents and users are provided with current guidelines if these have changed since publication pending updating and re-issue of AAPA Advisory Note 7. 2.6 Non-conforming products The manufacturer should have written procedures that specify how non-conforming products are dealt with. Any such non- conformances should be recorded and the records kept for the period dened in the manufacturers written procedures. Such written procedures are normally incorporated in a quality system. GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS 4 3. SAMPLING AND TESTING 3.1 General A means should be provided to safely take a representative sample from any point in the supply chain. All materials should be sampled in accordance with Austroads test method AG:PT/T101, Method of sampling polymer modied binders, polymers and crumb rubber, which provides for: Sampling of raw materials (polymer and rubber crumb) Sampling of PMBs: - From bulk storage - During loading - From rail and road tankers - From sprayers. It is important to ensure that samples collected are truly representative of the material being sampled. Therefore it is essential that PMBs are thoroughly circulated and polymers and rubber crumbs are thoroughly mixed prior to sampling to ensure they are homogeneous and that samples are representative. All bulk storage tanks should be tted with a sampling valve to facilitate sampling in accordance with AG:PT/T101. Sampling valves should be situated in a convenient and safe location for sampling and a permanent platform attached to support the sample container during lling. After lling, the sample container should be placed in a safe location and allowed to cool. The sample size should be sufcient to allow all required testing and generally will be at least one litre. Reheating of samples should be avoided. All sampling should be undertaken by properly trained and qualied personnel. The unit of competency on Safely Handling Bituminous Materials, which forms part of a Certicate II in Bituminous Surfacing, should be used as a guide to national competency training and assessment standards. Sampling should be accompanied by a visual check for uniformity, texture or unusual odour. Any observation of unusual sample characteristics should be recorded on the sample container. The following information should be provided with the sample, either on the label (see example Figure 2) or an accompanying form (see AG:PT/101 for full requirements): Designation or classication of the material being sampled Identifcation mark Name of supplier/manufacturer Date, time and location of sampling Type, batch number and identifying number of container, vehicle or storage tank from which the sample was taken Quantity of bulk material being sampled Temperature of material being sampled Name of sampler Any other comments. Figure 2: Example of sample label All samples should be handled in accordance with Austroads test method AG:PT/T102, Protocol for Handling Modied Binders in Preparation for Laboratory Testing. 3.2 Laboratory Testing Laboratory testing should be undertaken in a NATA accredited facility and in accordance with the relevant Austroads test methods. The types of tests and minimum frequency of testing should be in accordance with the requirements as set out in the Austroads Specication Framework for Polymer Modied Binders and Multigrade Bitumens (AG:PT/T190) or as agreed between the supplier and the purchaser.
Polymer Modified Binders Guide 6 September 2012 PMB SAMPLE Product name & grade _______________________ OLEXOBIT AB6 (A10E) Manufacturer ______________________________ BP Australia Date, time & location of sampling _______________ 22/4/2004 10:35 BP Altona Sample identification________________________ 1234 Batch / delivery docket number ________________ A04P0443 Tank / vehicle number _______________________ ALB201 Quantity & temperature of material being sampled _ 24,000 L at 186C Name of sampler ___________________________ Fred Jones Comments_________________________________ Sample for release testing
Figure 2: Example of sample label
All samples should be handled in accordance with Austroads test method AG:PT/T102, Protocol for Handling Modified Binders in Preparation for Laboratory Testing.
3.2 Laboratory Testing Laboratory testing should be undertaken in a NATA accredited facility and in accordance with the relevant Austroads test methods.
The types of tests and minimum frequency of testing should be in accordance with the requirements as set out in the Austroads Specification Framework for Polymer Modified Binders and Multigrade Bitumens (AG:PT/T190) or as agreed between the supplier and the purchaser.
3.3 Tracing Properties of Delivered Materials Experience and testing has shown that often a non-compliance in specified properties is due to degradation during transport, reheating, cleaning transfer lines and application procedures. From time to time protocols may be established for monitoring the properties of materials at the point of delivery or application. A flow chart of sampling, recording and testing is shown in Figure 3. These procedures may be used: As a project for the development and verification of handling protocols. Such projects may be conducted in association with a particular client (e.g. state road authority). To maintain product traceability. In this case field samples are not tested, but held in storage for reference testing for compliance with contract conditions. Samples are generally retained for the duration of the contract defects liability period.
In order to provide adequate traceability, delivery dockets for PMBs should generally contain the following information:
Date PMB Class Origin Sampling point Manufacturing certificate number or batch number
Polymer Modified Binders Guide 6 September 2012 PMB SAMPLE Product name & grade _______________________ OLEXOBIT AB6 (A10E) Manufacturer ______________________________ BP Australia Date, time & location of sampling _______________ 22/4/2004 10:35 BP Altona Sample identification________________________ 1234 Batch / delivery docket number ________________ A04P0443 Tank / vehicle number _______________________ ALB201 Quantity & temperature of material being sampled _ 24,000 L at 186C Name of sampler ___________________________ Fred Jones Comments_________________________________ Sample for release testing
Figure 2: Example of sample label
All samples should be handled in accordance with Austroads test method AG:PT/T102, Protocol for Handling Modified Binders in Preparation for Laboratory Testing.
3.2 Laboratory Testing Laboratory testing should be undertaken in a NATA accredited facility and in accordance with the relevant Austroads test methods.
The types of tests and minimum frequency of testing should be in accordance with the requirements as set out in the Austroads Specification Framework for Polymer Modified Binders and Multigrade Bitumens (AG:PT/T190) or as agreed between the supplier and the purchaser.
3.3 Tracing Properties of Delivered Materials Experience and testing has shown that often a non-compliance in specified properties is due to degradation during transport, reheating, cleaning transfer lines and application procedures. From time to time protocols may be established for monitoring the properties of materials at the point of delivery or application. A flow chart of sampling, recording and testing is shown in Figure 3. These procedures may be used: As a project for the development and verification of handling protocols. Such projects may be conducted in association with a particular client (e.g. state road authority). To maintain product traceability. In this case field samples are not tested, but held in storage for reference testing for compliance with contract conditions. Samples are generally retained for the duration of the contract defects liability period.
In order to provide adequate traceability, delivery dockets for PMBs should generally contain the following information:
Date PMB Class Origin Sampling point Manufacturing certificate number or batch number GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS 5 3.3 Tracing Properties of Delivered Materials Experience and testing has shown that often a non-compliance in specied properties is due to degradation during transport, reheating, cleaning transfer lines and application procedures. From time to time protocols may be established for monitoring the properties of materials at the point of delivery or application. A ow chart of sampling, recording and testing is shown in Figure 3. These procedures may be used: As a project for the development and verication of handling protocols. Such projects may be conducted in association with a particular client (e.g. state road authority). To maintain product traceability. In this case eld samples are not tested, but held in storage for reference testing for compliance with contract conditions. Samples are generally retained for the duration of the contract defects liability period. In order to provide adequate traceability, delivery dockets for PMBs should generally contain the following information: Date PMB Class Origin Sampling point Manufacturing certifcate number or batch number Customer Customer order number, etc. Delivery details (delivery point, time and temperature) Loading information (date, time, temperature) Quantity/Mass of delivery Product heating information (heating start time, fnish time, total heating time and temperature) Delivery date, time and temperature. Sampling and labelling of samples should be undertaken in accordance with Section 3.1.
Polymer Modified Binders Guide 7 September 2012 Customer Customer order number, etc. Delivery details (delivery point, time and temperature) Loading information (date, time, temperature) Quantity/Mass of delivery Product heating information (heating start time, finish time, total heating time and temperature) Delivery date, time and temperature. Sampling and labelling of samples should be undertaken in accordance with Section 3.1.
Figure 3: Sample traceability flow chart
No Fail Pass Yes Yes No
Binder production Release tests performed Retained sample for further testing, if required Binder carted direct to site
Heating en-route? Intermediate storage Sample taken Delivery to site Record time and temperature Record time & temperature Sample taken Sample taken Re-process Robert 15/9/12 7:14 PM Deleted: GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS 6 3.4 Material Safety Data Sheet (MSDS) Material Safety Data Sheets (MSDS) are used to provide the information required to allow the safe handling of substances used at work. MSDS must comply with the National Code of Practice for the Preparation of Material Safety Data Sheets, 2nd Edition [NOHSC:2011(2003)], published by the National Occupational Health and Safety Commission. Suppliers are responsible for provision of the MSDS which the manufacturer or importer has prepared. The MSDS addresses the safety of both personnel and the physical environment. 4. TRANSPORT, STORAGE AND APPLICATION OF PMBs 4.1 General handling and safety requirements PMBs are transported and applied hot. Safety and handling procedures that are applicable to hot bituminous materials also apply to PMBs and are described in detail in the Austroads Bituminous Materials Safety Guide, AP-G41/08. 4.2 Special requirements for PMBs In addition to the general handling and safety procedures applicable to all bituminous materials, attention should be paid to those issues which have the potential to cause a reduction in the quality and effectiveness of PMBs. These include: Effect of excessive temperatures, extended periods of storage at elevated temperatures, and/or multiple reheating cycles. Potential for contamination during change of product in transportation vehicles and storage tanks. Potential for contamination with materials used for cleaning and ushing supply lines. Potential for some PMB mixtures to segregate in storage. Method of reheating, e.g. need to recirculate product while reheating. As a further conrmation that PMBs have not suffered undue deterioration during transport, samples may be required of the product at the point of delivery or immediately prior to use in asphalt mixtures or sprayed sealing work (see Section 3.3). 4.2.1 Temperature PMBs should not be heated to, stored or held at temperatures or for periods greater than that recommended by the manufacturer. During handling, every effort should be made to keep the PMB at the minimum temperature that will allow effective use so that the risk of thermal degradation and oxidation is minimised. Similarly, the time that the PMB is kept at elevated temperatures prior to application should be minimised. AAPA Advisory Note 7 should be taken as a guide to the maximum application temperature, holding time at maximum application temperature, storage temperature and maximum time at recommended storage temperature. PMBs should never be heated to a temperature greater than the recommended maximum application temperature. Generally, only the quantity required for immediate use should be heated to the application temperature and reheating avoided, where practicable. 4.2.2 Moisture The presence of even small quantities of water can cause foaming and boil-over of hot PMB. Care should be taken to ensure that road tankers, storage tanks or bitumen sprayers are free from water arising from the presence of condensation or residual bitumen emulsion. A visual check for condensation should always be made where tanks have been out of service for some time. 4.2.3 Cleaning materials It is preferable to use diesel or high-ash kerosene to ush lines. The amount of cleaning material should be kept to a minimum and drained from tanks and delivery lines for separate disposal in accordance with local requirements. Cleaning materials should not be ushed into binder storage tanks or delivery vehicles. Kerosene or other types of approved cutter oil used for cleaning delivery lines may be drawn into bitumen sprayers where the PMB is being prepared for spraying. An allowance for the quantity of cutter oil used for cleaning should be made in determining the total quantity of cutter oil to be added. 4.2.4 Segregation Some PMB types, particularly those modied by rubber crumb or high levels of SBS polymer, are susceptible to segregation during long distance transport and long term storage. Manufacturers should advise users of susceptible materials and provide guidelines for minimising segregation and/or remixing. Users should adhere to manufacturers guidelines where applicable. The use of stirrers in storage tanks and belly augers in sprayers will help ensure homogeneity can be maintained for PMBs that are susceptible to segregation. GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS 7 4.2.5 Loading of delivery vehicles Vehicles used to transport PMBs should be emptied of the previous product to the minimum practical level to minimise contamination. Comprehensive guidance on the procedures to follow when changing grades carried within a road tanker is provided in AP-G41/08. A summary of product changeover procedures relevant to PMBs is provided in Table 1. Particular attention needs to be paid when loading hot PMB into a tanker that has previously contained a bitumen emulsion due to the potential for hazardous foaming and boil-over of the tank contents. Vehicles previously used for delivery of bitumen emulsion products should not be used for the delivery of PMB unless thoroughly cleaned. The risk of subsequent product contamination is particularly high when vehicles have been used to transport PMBs incorporating rubber crumb. It is recommended that such binders be transported only in dedicated tankers. Care should be taken to ensure that tankers that have not been in use for some time are free from condensation.
Notes to Table 1: OK: OK to load. In all cases the previous product should be fully drained. Drain & Flush: Drain vehicle of product and ush with kerosene wash and fully drain and dry out, or boil out with uncontaminated standard grade bitumen as per your companys work instruction. 4 standard Should take minimum 4 loads of C170, C320 bitumen loads: or C600 prior to loading. 4.2.6 Reheating during transport Delivery vehicles can generally transport materials for periods of up to 4 to 6 hours with only a minor loss in temperature, usually no more than about 15C. Where there is only a small loss in temperature, PMBs may be transferred directly into storage tanks without reheating or, where the PMB is required to be at an application temperature, for example delivery direct to sprayed sealing operations, they may be reheated in the delivery vehicle prior to transfer into the bitumen sprayer. Where longer transport times and greater loss of temperature are involved, materials should be periodically reheated to ensure that temperature is maintained within the recommended limits. For convenience, this may be done in conjunction with regular rest stops. The following points should be noted when reheating PMBs: 1. At no time should the recommended maximum temperature for the material be exceeded as indicated in Advisory Note 7. 2. Bitumen road tankers or sprayers tted with open ame burners should never be heated while in motion. 3. Drivers should be in attendance and monitor the process at all times while burners are in operation. 4. To avoid PMB degradation, the preferred rate of heating should be approximately 10C per hour and not more than 15C per hour. 5. Tankers should be circulated during heating and for at least 20 minutes after heating and before discharge. 6. Generally, temperature checks should be undertaken every four hours and reheating applied when the temperature drop is greater than 15C. 7. For PMBs incorporating 15% or higher rubber crumb content, circulation should be continuous during transport and heating with the temperature being maintained within the range recommended by the manufacturer and checked at intervals not exceeding 3 hours.
Polymer Modified Binders Guide 10 September 2012 Table 1: Product changeover guidelines Previous Load PMB Bitumen OK Cutback bitumen primers & precoats Drain Bitumen emulsion Drain & flush Fuel oil Drain & flush Suspected presence of moisture Drain & flush PMB OK Crumb rubber bitumen 4 Standard bitumen loads* Other X
Notes to Table 1: OK: OK to load. In all cases the previous product should be fully drained. Drain & Flush: Drain vehicle of product and flush with kerosene wash and fully drain and dry out, or boil out with uncontaminated standard grade bitumen as per your companys work instruction. 4 standard bitumen loads: Should take minimum 4 loads of C170, C320 or C600 prior to loading.
X: Refer to supplier for technical advice.
4.2.6 Reheating during transport Delivery vehicles can generally transport materials for periods of up to 4 to 6 hours with only a minor loss in temperature, usually no more than about 15C. Where there is only a small loss in temperature, PMBs may be transferred directly into storage tanks without reheating or, where the PMB is required to be at an application temperature, for example delivery direct to sprayed sealing operations, they may be reheated in the delivery vehicle prior to transfer into the bitumen sprayer.
Where longer transport times and greater loss of temperature are involved, materials should be periodically reheated to ensure that temperature is maintained within the recommended limits. For convenience, this may be done in conjunction with regular rest stops.
The following points should be noted when reheating PMBs:
1. At no time should the recommended maximum temperature for the material be exceeded as indicated in Advisory Note 7. 2. Bitumen road tankers or sprayers fitted with open flame burners should never be heated while in motion. 3. Drivers should be in attendance and monitor the process at all times while burners are in operation. 4. To avoid PMB degradation, the preferred rate of heating should be approximately 10C per hour and not more than 15C per hour. Refer to supplier for advice GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS 8 4.2.7 Delivery into storage tanks or bitumen sprayers (a) Asphalt plants and other xed storage Where a PMB is placed in a storage tank previously used for hot bitumen, multigrade bitumen or a different grade of PMB, the tank should be emptied to the minimum practicable level in order to minimise any diluting effect on the polymer content of the delivered PMB. Where the residual contents of a storage tank comprise a different grade of PMB or other modied binder, the manufacturers advice should be sought on any potential incompatibility with the fresh product. Table 2 provides a guide to the relative risk from contamination by previous tank contents (b) Road tankers, mobile storage tanks, and bitumen sprayers used for sprayed sealing work Road tankers, mobile storage tanks or bitumen sprayers previously used for uxed or cutback bitumen should be totally emptied before lling with PMB (see also Section 4.2.5). Notes to Table 2 1. Risk prole: Low Residual tank contents have a low risk of performance impact on the product being added, for example topping up of modied binder with hot bitumen may enhance rather than detract from normal use of bitumen. Medium While residual tank contents may not have a major impact on performance of added product, tank levels should generally be reduced to minimum levels before adding new materials. High Reduction of tank contents to minimum level is essential. Low levels of contamination may be tolerated but generally not more than 10% of diluting product. Very high Contamination could have a serious impact on performance. Preferably, the tank should be completely emptied prior to adding new materials. Where complete emptying is not practicable, risk should be reduced by ushing the tank with 4.2.8 Field sampling Representative samples may be required to be taken of a PMB prior to its use. Such samples should be taken during ofoading of road tankers and during transfer into bitumen sprayers prior to the addition of cutters and adhesion agents. In the case of asphalt manufacture, a sample can be taken from the PMB storage tank or from the ring main during circulation or use. Field samples should be taken at locations and frequencies as agreed between supplier and purchaser. All sampling should be performed in accordance with the procedures described in AG:PT/T101. Field samples should be clearly identied to provide traceability from supplier to the point of sampling. Unless otherwise specied or directed, eld samples are not required to be tested immediately and should be stored in sealed containers in a secure location for a minimum period of six months, or for the duration of the contract defects liability period, whichever is the greater. Samples not required for further testing beyond that period may then be discarded. a more compatible material or using the tank, for example, with a load or part load of hot bitumen or PMB in an application where the performance properties of the PMB are not critical. 2. Storage of bitumen emulsion in tanks previously used for hot bitumen products usually requires the tank to be completely emptied and cleaned before adding bitumen emulsion. 3. Hot bituminous materials should not be added to tanks previously used for bitumen emulsion unless all traces of moisture have been removed. 4. Care should be taken when adding materials to tanks that have been used for storage of crumb rubber modied binder. Usually a series of loads of hot bitumen or hot cutback bitumen are required before use for any other critical application. 5. Multigrade to be treated the same as bitumen for product changeover purposes 6. Refer to AP-G41/08 Austroads Bituminous Materials Safety Guide for specic requirements
Polymer Modified Binders Guide 11 September 2012 5. Tankers should be circulated during heating and for at least 20 minutes after heating and before discharge. 6. Generally, temperature checks should be undertaken every four hours and reheating applied when the temperature drop is greater than 15C. 7. For PMBs incorporating 15% or higher rubber crumb content, circulation should be continuous during transport and heating with the temperature being maintained within the range recommended by the manufacturer and checked at intervals not exceeding 3 hours.
4.2.7 Delivery into storage tanks or bitumen sprayers (a) Asphalt plants and other fixed storage Where a PMB is placed in a storage tank previously used for hot bitumen, multigrade bitumen or a different grade of PMB, the tank should be emptied to the minimum practicable level in order to minimise any diluting effect on the polymer content of the delivered PMB. Where the residual contents of a storage tank comprise a different grade of PMB or other modified binder, the manufacturers advice should be sought on any potential incompatibility with the fresh product. Table 2 provides a guide to the relative risk from contamination by previous tank contents.
Table 2: Relative risk from contamination by previous tank contents Product being delivered Previous tank contents Cutback bitumen Bitumen emulsion Bitumen Low modification PMB High modification PMB Crumb rubber bitumen Cutback bitumen Not applicable See note 2 Medium Very high Very high High Bitumen emulsion See note 3 Note 6 See note 3 See note 3 See note 3 See note 3 Bitumen Medium See note 2 Not applicable Medium High Medium Low modification PMB Medium See note 2 Low Not applicable Medium Medium High modification PMB Medium See note 2 Low Medium Not applicable Medium Crumb rubber bitumen See Note 4 See note 2 See Note 4 See Note 4 See Note 4 Not applicable
Notes to Table 2 1. Risk profile: Low Residual tank contents have a low risk of performance impact on the product being added, for example topping up of modified binder with hot bitumen may enhance rather than detract from normal use of bitumen. Medium While residual tank contents may not have a major impact on performance of added product, tank levels should generally be reduced to minimum levels before adding new materials High Reduction of tank contents to minimum level is essential. Low levels of contamination may be tolerated but generally not more than 10% of diluting product. Very high Contamination could have a serious impact on performance. Preferably, the tank should be completely emptied prior to adding new materials. Where complete emptying is not practicable, risk should be reduced by flushing the tank with a more compatible material or using the tank, for example, with a load or part load of hot bitumen or PMB in an application where the performance properties of the PMB are not critical. 2. Storage of bitumen emulsion in tanks previously used for hot bitumen products usually requires the tank to be completely emptied and cleaned before adding bitumen emulsion. 3. Hot bituminous materials should not be added to tanks previously used for bitumen emulsion unless all traces of moisture have been removed. GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS 9 5. ASPHALT WORK 5.1 General PMBs for asphalt work should be transported, transferred and stored in accordance with Section 4. 5.2 Production of asphalt mixes Asphalt produced from pre-blended PMB should be mixed and handled in accordance with the recommendations of the PMB manufacturer/supplier. Such recommendations may refer to asphalt mixing temperatures, mixing times and specic measures to minimise heat loss during transit. Asphalt incorporating a PMB can also be produced by the addition of rubber crumb and other selected granular polymers into the asphalt mixing process, but only in a batch type pugmill or double drum mixer. Addition of some polymers, such as EVA and rubber crumb, direct to the pugmill should also be in accordance with the recommendations of the polymer supplier. Increased wet mixing times may be required to achieve a satisfactory distribution of the polymer through the asphalt mixture. The modication of bitumen generally results in an increase in the binder viscosity and therefore the asphalt mixing temperature may need to be increased to ensure adequate coating of the aggregate and workability of the asphalt. Inappropriately high asphalt mixing temperatures may lead to segregation, binder degradation and binder drainage, which in turn can adversely affect performance of the asphalt. Excessive temperatures may also cause unwanted fuming. Refer to AAPA Advisory Note 7 for details of the appropriate asphalt production and paving temperatures for the various PMBs. 5.3 Placement and Compaction Additional care is needed to achieve specied requirements for riding quality, compaction and surface nish when placing and compacting asphalt incorporating PMB. To achieve adequate compaction, the mix temperature may need to be increased by up to 15C over conventional bitumen, depending on the type and degree of modication. Loss of workability on cooling will necessitate greater attention to: weather conditions; layer thickness and mix type; timing of operations; rolling patterns and techniques; scheduling of deliveries (avoid starts and stops); joints (minimise); handwork (to be avoided); and prevention of pick-up on rubber-tyred rollers (pre-heat). Some PMBs emit fumes at high temperatures. Such fumes can lead to eye and throat irritation, or even to headaches and nausea. Therefore, it is important to follow the manufacturers recommendations with regard to handling conditions and the use of appropriate personal protective clothing and equipment. The AAPA Guide to the safe use of SBS, AAPA Advisory Notes 7 and 14, Austroads/AAPA Work Tip 13 and AAPA training programs address such issues and provide a guide to best practice. Further guidelines for the use of PMBs in asphalt are provided in the Austroads Guide to the Selection and Use of Polymer Modied Binders and Multigrade Bitumen AP-T42-06 6. SPRAYED SEALING WORK 6.1 General PMBs for sprayed seal work should be stored, transported and transferred in accordance with Section 4. Any increase in binder cohesion (internal strength) as a result of polymer modication usually is accompanied by a decrease in binder wetting ability and therefore its ability to adhere to, or retain aggregate. These characteristics require modication to eld procedures as described in the following section. 6.2 Field procedures 6.2.1 General handling requirements for PMBs PMBs are generally handled and applied similarly to Class 170 bitumen using conventional sprayed sealing equipment. However, PMBs require increased attention to detail and special consideration of the eld construction practices to ensure satisfactory adhesion between the binder and the aggregate. PMBs are more viscous than Class 170 bitumen and may form a skin in cooler weather conditions. For details on the appropriate minimum road surface and binder spray temperatures for the various PMBs, refer to either the PMB supplier or the AAPA Advisory Note 7. In addition to normal good practice, the following procedures should be followed: The time taken to spread aggregate onto a PMB must be kept as short as practically possible and the aggregate spreading and rolling operations should be kept as close as possible behind the sprayer. This is done to ensure aggregate adhesion has the best chance of developing while the PMB is still hot and may necessitate shorter than usual sprayer runs or additional rolling capacity. GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS 10 If using a particular class of PMB for the frst time, it is advisable to check with the manufacturer about any special handling or application requirements. For a SAM or SAMI application, the pavement and air temperatures need to be above 20C and rising. Higher temperatures are required if wind chill is expected to cool the binder quickly after spraying. Wind chill will cause the binder to skin more quickly and this will delay, or prevent, wetting and development of adhesion. The exception to this is S35E produced with PBD, which may be used at the lower pavement and air temperatures normally accepted for Class 170 work (approximately 15C), but only where recommended by the manufacturer. The presence of moisture in any form should be avoided. Avoid spraying PMBs in changeable weather conditions. Spraying should only be applied to a dry pavement surface and aggregates should be precoated and dry (at most damp). This may require the aggregate stockpile to be covered with waterproof material. Warm and dry weather conditions before and after application of the PMB seal are essential. Wet weather up to a week after application may result in the aggregate stripping. Spraying should not be undertaken if wet weather is predicted within several days after application. Adhesion agent should be added to the PMB in the sprayer no more than half an hour prior to spraying and the load thoroughly circulated. Exceptions may apply to a few specic heat stable adhesion agents known to retain effectiveness after several hours at high temperatures. Such materials should only be used in accordance with the suppliers recommended maximum temperature and storage times. The PMB/aggregate/precoating material/adhesion agent system should be evaluated, well in advance of the work, using both the initial adhesion and plate stripping tests. Check with the manufacturer if unsure of the details. Cutter oils are generally required to facilitate spraying of PMBs and wetting of aggregate. Some of the more viscous PMBs will require the use of larger spray nozzles; e.g. B6 or B8 nozzles, depending on binder viscosity, to ensure a uniform transverse binder application. 6.2.2 Cutter A summary of the requirements for cutting back of PMBs is provided in Austroads/AAPA Work Tip No. 27 Sprayed Sealing Cutting Back of Polymer Modied Binders. Additional advice on cutting back of PMBs and other sprayed sealing construction practices are provided in the Austroads Guide to the Selection and Use of Polymer Modied Binders and Multigrade Bitumens or may be obtained from manufacturers or suppliers. Take extreme care when blending cutter oil with PMB. AP-G41/08 should be consulted for further information. 6.2.3 Adhesion Agent In general, hot PMBs are more viscous and cohesive than conventional bitumen and consequently less able initially to wet and adhere to aggregate particles. If there are problems developing adequate adhesion between the PMB and the aggregate, then it is recommended to promote bonding by adding extra adhesion agent. A general rule of thumb in this case is to double the concentration of adhesion agent compared to conventional bitumen, i.e. add about 1% of adhesion agent instead of 0.5%. The adhesion agent selected should be compatible with the type of polymer in the binder and the aggregate precoating material. 6.2.4 Aggregate Precoating It is important to only use aggregate that is of good quality and that is dry and free from dust. It is also important to adhere to recommended cutting practice. This applies to all PMB seals, including those applied on lower trafc volume roads. However, initial adhesion of PMB to the aggregate particles may still be difcult to achieve, especially with increasing concentrations of polymer and rubber crumb. It is therefore essential to precoat the aggregate, preferably with a bitumen-based precoat that contains about 1% of adhesion agent. This should ensure both effective initial adhesion and longer term retention of the aggregate. GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS 11 REFERENCE AAPA (1998) Advisory Note 14 Summary of SBS Bitumen Fume Monitoring Project. AAPA (1998) HS&E Guide No 5 Guide to the safe use of SBS. AAPA (2004) Advisory Note 7 Guide to the Heating and Storage of Binders for Sprayed Sealing and Asphalt Manufacture. AUSTROADS (2000) AP-T42/06 Guide to the Selection and Use of Polymer Modied Binders and Multigrade Bitumens. AUSTROADS (2006) AG:PT/T101 Method of Sampling Polymer Modied Binders, Polymers and Crumb Rubber. AUSTROADS (2008) AG:PT/T102 Protocol for Handling Modied Binders in Preparation for Laboratory Testing. AUSTROADS (2008) AP-G41/08 Austroads Bituminous Materials Safety Guide. AUSTROADS (2010) AGPT/T190 Specication Framework for Polymer Modied Binders and Multigrade Bitumens. AUSTROADS/AAPA (1998) Pavement Work Tip No. 13 Temperature Characteristics of Binders in Asphalt. AUSTROADS/AAPA (2001) Pavement Work Tip No. 27 Sprayed Sealing Cutting Back of Polymer Modied Binders. NOHSC:2011(2003) National Code of Practice for the Preparation of Material Safety Data Sheets 2nd Edition. Austroads test methods and selected Austroads Technical Reports may be accessed and downloaded, free of charge, from the Austroads web-site at www.austroads.com.au. AAPA Advisory Notes, HS&E Guides, and Austroads/AAPA Work Tips may be accessed and downloaded, free of charge, from the AAPA web-site at www.aapa.asn.au. GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS 12 GLOSSARY Adhesion agent A substance used for the purpose of improving the adhesion between a bituminous binder and the aggregate. The term generally refers to adhesion in the presence of water. asphalt (used rather than the US term asphaltic concrete) A mixture of bituminous binder and aggregate with or without mineral ller, produced hot in a mixing plant, which is delivered, spread and compacted while hot. bitumen A very viscous liquid or a solid, consisting essentially of hydrocarbons and their derivatives, which are soluble in carbon disulphide. It is substantially non-volatile and softens gradually when heated. It possesses waterproong and adhesive properties. It is obtained from native asphalt or by processing the residue from the rening of naturally occurring crude petroleum. bitumen emulsion A liquid product in which a substantial amount of bitumen (with which some oil may be mixed) is suspended in a nely divided condition in water by means of emulsifying and stabilising agents. crumb rubber Rubber particles manufactured from waste or reclaimed rubber products such as vehicle tyres and graded to conform to a specied size range. Used in bitumen to improve binder properties. cutback bitumen Bitumen to which cutter oil (kerosene) has been added to achieve a temporary reduction in viscosity. cutter (kerosene) A light petroleum distillate added to bitumen to temporarily reduce its viscosity (cutback bitumen). A high-ash cutter is a cutter with a ash point above 60C. material safety data sheet (MSDS) A document that provides health and safety information about products, substances or chemicals that are classied as hazardous substances or dangerous goods. multigrade bitumen A bituminous binder which, at high service temperatures shows good resistance to ow, and at low temperatures does not exhibit the high stiffness (leading to brittleness) normally experienced with conventional bitumen binders. polymer A predominantly organic substance comprising a very large number of chemical entities. These chemical entities may comprise identical segments (producing a homopolymer) or a combination of two or more different segments (producing a copolymer). polymer modied binder (PMB) A binder consisting of polymeric materials dispersed in bitumen with enhanced binder performance for particular applications. sprayed seal (chip seal) A thin layer of binder sprayed onto a pavement surface with a layer of aggregate incorporated and which is impervious to water. strain alleviating membrane (SAM) A sprayed seal with the binder containing a relatively large concentration of rubber or polymer modier. It is used to absorb strains that occur in a road pavement and thereby reduce reection cracking. strain alleviating membrane interlayer (SAMI) Similar to a SAM, but provided as an interlayer before placing an asphalt overlay.
GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS The Australian Asphalt Pavement Association is a non-prot organisation formed to promote the economic use of asphalt and bitumen bound products based on sound technical and commercial grounds. Throughout its history, AAPA has maintained as its major objective thedissemination of technical knowledge aimed at continual improvement in Asphalt technology. AAPA Members include manufacturers of asphalt and other bitumen bound products, State Road Authorities, Local Government, pavement engineering consultants, material suppliers, plant and machinery manufactures paving and sealing contractors and individuals interested in asphalt technology. Level 2, 5 Wellington Street Kew Victoria 3101 AUSTRALIA Telephone: (03) 9853 3595 Fax: (03) 9853 3484 Email: [email protected] Web: www.aapa.asn.au