Technical Guidelines:

Construction of
bitumen rubber seals
TECHNICAL GI]IDELINES

CONSTRUCTION OF BITUMEN RUBBER SEALS

Published by
Sabita
P O Box 6946
Roggebaai
8012

Fintpublished
 Preface to first edition

Bitumen-rubber was first introduced in South Africa in 1982 at a time

when financial restraints encouraged the adoption of innovative
practice. The market proved particularly receptive to this product,
since it was perceived to be a cost-effective option in situaiions where
conventional seals were not expected to perform satisfactorily.

Bitumen-rubber differs substantially in its composition and manufac-

ture from conventional binders. These differences made it difficult to
determine appropriate tests and performance criteria. Accordingly at
the NITRR Bituminous Materials Liaison Committee meeting in May
1983 the urgent need for a national specification for this materiar was
recognised.

The Technical committee on Bitumen-Rubber was founded under the

chairmanship of the Southern African Bitumen and rar Association
(SABTA) to address the above need. This commitee has a broad
spectrum of membership representing the Department of Transport
(DOT), Provincial Roads Departments, National Institute for Trans-
port and Road Research (NITRR), SA Bureau of Standards, South
African Air Force, south African Association of consulting Engineers
(SAACE), Departmenr of Development Aid, Much Asphati
lfrty; I-ta,
Protea Asphalt (Pty) Ltd and Tbsas (pty) Ltd.

The committee functions in a spirit of close co-operation and provides

an invaluable impetus to furthering knowledge and developing
appropriate test procedures and criteria. It has also initiated the
compilation of a number of documents on the subiect, the first of
yhi:-tr "Interim Specification - Bitumen-Rubber for Spray Applica-
tion", was published by SABTA in March 1984.

This document offers guidance as to the correct construction of

bitumen-rubber seals. It is effectively addressing a need recognised for
some time and it is expected to have a marked input on the efficacy of
future bitumen-rubber applications.

44/-,
P A MYBURGH V P SERVAS
C hairman: Technical C ommitue Chairmnn: Sub-C ommiuee on
on Bitumen-Rubber Technical Guidelines
2
Preface to second edition
Since the publication of the frst edition in 1987 the work by this
committee has yielded no less than three additional manuals rBlated to
bitumen-rubber binders, being: Mantnl3.'Test methods for $itumen-
rubber used in sealsl Maruul 4: Specification for rubber crumb for use
in bitumen-rubber binders; and Mannl 6.' Interim specifipation -
bitumen-rubber road binder for spray application.

The production of these manuals has rendered some of the contents in

section I - Materials, superfluous in that reference to the'relevant
manual is now more aPProPriate.

Also, in the light of experience gained in the application of bitumen-

rubber seals, some amendments have been made to section 2, - Plant
and Equipment, section 4 - Construction, and particularly to $ection 5
- prociss control, where appropriate reference is made to the lrelevant
manuals in respect of lateral distribution of the spray appliQation of
binder distributors.

Organisations cutrently rcpresented on the Technical Comtqittee for

Mdifud Bhden arc:
Abecol (Pty) Ltd
B P SA (Pty
Cape Roads Department
CSRA Highway Materials Sub-committee
Department Development Aid
Department of TransPort
Oivision of Roads and Transport Technology' CSIR
Much Asphalt (Pty) Ltd
Natal Roads Department
Protea Asphdt (Pty) Ltd
SA Association of Consulting Engineers
SA Bitumen and Tar Association
SA Bureau of Standards
Shell SA (Pty) Ltd
Tosas (Pty) Ltd
Transvaal Roads DePartment

4,{a/r
P A MYBURGH
C haimun : Technical C omrnitte e
on Modifuil Binders
Contents

l. Materials 6

2. Plant and Equipment 8

3. Preparation of areas to be surfaced l0

4. Construction ll
5. Process and control t4
 Scope
This document comprises recommendations on materials and methods
of construction for surface treatments in which a bitumen-rubber
binder is used. It includes, in particular, recommendations on the
bitumen and the rubber to be used, on the preparation and properties
of the bitumen-rubber blends and on their handling and storage during
construction.

I. MATERIALS

l.l Aggregates
The nominally single-sized aggregate (19,0 mm, 13,2 mm or 9,5 mm)
should consist of approved crushed stone complying with the
requirements of SABS specification 1083 in respect of grading,
hardness and flakiness.

1.2 Precoating of aggregate

The untreated aggregate should be sprayed thoroughly with water and

allowed to drain. The aggregate should then be uniformly coared,
using a mechanical mixer or other approved means, with precoating tar
or similar approved material, using the following amounts of coating
material.

Nominal size of aggregate Amount of coating material

(mm) (um3)
19,0 l0
13,2 n
9,5 I2

This procedure may be used for aggregate intended for immediate use
or for stockpiling. After coating the aggregate should be placed on a
stockpile site complying with requirements set out below (1.3) A
stockpile may be built up in batches of l5-20m3.

During the wet season, where there is a danger of the precoating fluid
being washed off the aggregate, the stockpile must be covered with
tarpaulins or similar protective coverings.

1.3 Stockpiling of aggregate

sites for the stockpiling of aggregates should be hard surfaced, self

draining and prepared in such a manner that no vegetation, mud, dirt
6
NorE: lf precoated aggregate is used before it dries it is susceptible to water and stripping
ofaggregate is possible ifrain falls before the aggregate dries.
or other deleterious materials will be included when the aggregates are
loaded for use.

Access to stockpile sites should be such that no dirt is conveyed by

vehicle wheels on to the areas to be surfaced or resurfaced whilst
aggregate is being transported to or from the stockpiles.

Stockpiles should be sited so as not to be exposed to excessive

contamination with dust arising from nearby construction traffic on the
road or access roads. Aggregate contaminated to the extent that it
contains more than the allowable percentage of material passing the
01425 nn sieve should not be used for surface treatment work.

1.4 Bitumen-rubber binder

L.4.1 Bfumen

The bitumen should be a penetration grade bitumen which complies

with the requirements of SABS 307 for either 60/70, 80/100 or 150/200,
or which is a blend of any two or all three grades to provide for a
product having an intermediate penetration.

I.4.2 Rubbq

The rubber should comply with the requirements of Manual 4:

Specification for rubber crumb for use in bitumen-rubber binders,
published by the SA Bitumen and Tar Association.

1.4.3 Extndq oil and dihunt

Extender oil is a petroleum derived material of high aromaticity.

A diluent is a petroleum hydrocarbon distillate.
Appropriate safety precautions should be followed with regard to flash
points.

1.4.4 Bitumm-rubber blend

The bitumen-rubber blend, containing where necessary extender oil

and/or diluent, should comply with the requirements of Manud 6:
Interim specification - bitumen-rubber road binder for spray applica-
tion, published by the SA Bitumen and Tar Association.

1.5 Heating and storage of bitumen-rubber binder.

Since the rheological properties of bitumen-rubber may changeduring

7
hot storage, attention of the user is drawn to appendix B, specifically
section B-2.1, of manual 6 referred to above.

Bitumen-rubber stored in a heated condition should'be kept in a

container having a properly functioning circulation/mixing system and
a securely fitting lid.

2. PLANT AND EQUIPMENT

2.1 General

All plant and equipment that will be operated on the road during
construction of the surface treatment should be of adequate rated
capacity, in good working condition and free of any binder, fuel or oil
leaks. No refueling or servicing of any such equipment should be
allowed to take place while on the road.

2.2 Bitumen distributor

The bitumen distributor should be certified by a Provincial Roads

Department that it complies with the Department's requirements for
bitumen distributors.

In addition, the distributor should be capable of spraying bitumen-

rubber within the percentage tolerances given in TMH2.

2.3 Chip spreaders

The chip spreaders should be capable of spreading the stone uniformly

over widths variable between 2,4 m and,4 m and should be capable of
adiustment to permit variation of the rate of application.

At least two chip spreaders should be provided of which one, in the

case of single bituminous surface treatment) should be a self.propelled
machine.

Any spreaders not self-propelled should be of a type that can be

attached quickly to the rear of a truck and operated while being backed
over the layer of chips already spread.

2.4 Rollers

Enough rollers of each of the following types should be available to

maintain the required tempo of work:

8
2.4.1 Prcumaic-tyred rollcrs

Pneumatic-tyred rollers should be of a self-propelled type equipped

with smooth pneumatic tyres of uniform size and diameter. The mass
of the roller should not be less than 15 tons.

The rollers should be equipped with suitable devices for keeping the
wheels clean during operation.

The wheels of the roller should be so spaced that one pass of the roller
will provide one complete coverage equal to the rolling width of the
machine. The total operating mass and tyre presssure may be varied by
the engineer at his discretion. Individual tyre pressure should not
differ from one another bv more than 35 kPa.

2.4.2 FIat steel rollers

Flat steel rollers should be self-propelled three-wheel or tandem rollers

of between 6 and 8 tons mass and should be equipped with suitable
devices for cleaning the wheels. The mass of the roller required should
be determined by the engineer.

2.5 Brooms

2.5.1 Drag broom

The drag broom should be of a size, type and mass which will enable
the chips to be distributed evenly over the surface without dislodging
stone chips from the binder film.

2.5.2 Rotary broont

An approved rotary broom with towing vehicle fitted with pneumatic

tyres, should be available at all times on the works.

2.6 Front-end loader

A front-end loader of adequate capacity to ensure a continuous supply

of aggregate from the stockpiles into the trucks should be available.
The engineer should have the right to call for a standby loader if there
is any doubt about the efficiency or capacity of the front-end loader
provided.
2.7 Miscellaneous equipment

Enough equipment for handling and hauling aggregate should be

provided to ensure prompt and continuous covering of the binder film
as specified. The contractor should have available all the necessary
ancillary equipment and hand tools to carry out the work efficiently.

Suitable fire fighting equipment for dealing with both bitumen-rubber

and rubber crumb fues should be available on site, together with
suitable first aid equipment for dealing with bitumen-rubber burns.

2.8 Blending unit

Where the mixing of bitumen and rubber crumb is done on site it

should be done either in a purpose designed in-line blending unit or in
a distributor, suitably modified to act as a blending unit, and be done
under the supervision of the supplier of the materials.

3. PREPARATION OF AREAS TO BE SURFACED

3.1 General

The areas to be surfaced should be dry and free of all dust, dirt, dung,
oil or any other foreign materials that will be deleterious to the
surfacing.

3.2 Newly constructed surfaces

Vhere newly constructed areas are to be surfaced, these should be

checked for compliance with the surface tolerances and other
requirements specified. Any portions that do not meet these require-
ments should first be either corrected or removed and reconstructed
before they are surfaced.

3.3 Existing surfaces to be resealed

Existing roads that require resealing should, if so specified or ordered

by the engineer, be given a pre-treatment in accordance with one or
more of the methods described in existing specifications.

Any maior failures should be repaired as specified in the special

provisions or existing specifications.

l0
3.4 Demarcation of working area

Immediately before the binder is sprayed, the centre line of the road
should be marked by 3 mm thick sisal or hemp twine, secured by nails
driven into the existing surface at 15 m intervals on straights and 5 m
intervals on curves.

4. CONSTRUCTION

4.1 Weather conditions

The minimum road surface and air temperatures at which the spraying
of bitumen-rubber can be done are:
Road temperature 20 "C
Air temperature (day) 15 'C
Both these mininum conditions should be met. It is highly probable
that the minimum air temperature at night will be less than 8 "C in
certain areas during the winter months. If previous meteorological data
shows this to be the case then no bitumen-rubber spray work should be
undertaken.

$fhen strong winds are blowing and this is likely to interfere with the
proper execution of the work, no surface treatment work should be
done.

4.2 Application of binder and aggregate

Prior to the start ofthe construction, and after testing of the aggregates
the contractor proposes to use, the actual rates of application of binder
and aggregate to be used will be determined by the engineer'

Before commencing spray operations it should be ensured that all

required plant and material are available and ready for use, and that the
prevailing weather conditions are acceptable.

It is advisable ro spray the binder at a temperature not less than 175 "C.
Immediately aftei thl binder has been sprayed, it should be covered
with pre-coated aggregate by means of chip spreaders'

In the case of single surface treatment, the use of a self-propelled chip

spreader should be obligatory. chip spreaders should commence
spreading the aggregate as closely as possible behind the bitumen
distribut6r in suitr m"nn.r that the binder film is covered with
"
ll
 aggregate before the wheels of the chip spreader or truck pass over the
uncovered binder film. All aggregate should be spread within 15
minutes of application of the binder. The total quantiry of binder
sprayed in any single spray operation should be governed by the
quantity of aggregate and the number of trucks available, which are
sufficient to ensure the continuous applications ofaggregate behind the
distributor within the limits prescribed above.

The application rate of the aggregate sirould not vary by more than 5
per cent from the specified rate.

The application rate for the bitumen-rubber binder should also nor
vary by more than 5 per cent from the specified rate. Unless otherwise
specified, check measurements of the rate of application of the binder
should be made at spraying temperature.

4.3 Initial rolling

Initial roiling should commence immediately behind the chip spreader

and the roller should maintain a distance of not more than l0 m behind
the spreader on the first pass.

Any areas deficient in aggregate should have additional material added

so as to leave the carpet with a single layer of aggregate lying shoulder
to shoulder. It is esscntial to ensure that only one layer of aggregate is
applied and cvery care should be raken to avoid over-application of the
aggrcgate.

4.4 Final rolling

The final rolling should be done with a 15 to 20 ton pneumatic-tyred

roller only, applying a minimum of four coverages.
'fhe finished surface should be well-knir and have a uniform
appearance free of roller tyre marks.
All aggregate conraminared by oil,
fuel grease should be removed and replaced by clean pre-coated
'r
aggrcgate.

All loose aggregare should be broomed off the surface with a rotarv
broom or hand brooms as directed by the engineer.

4.5 Joints between binder sprays

In order to prevent overlapping transverse junctions of separate binder

applications, the previous work along the transverse joint should be
t2
covered with twine reinforced building paper for a sufficient distance
back from the ioint. This is to ensure that the sprayer is operating at
the required rate before the untreated surface is reached, and also to
preu.ni additional binder application onto the previously treated
iection. The same method should be used to ensure a neat ioint at the
end of the run.

Ideally, longitudinal joints should not be left unmarried at the end of a

working day and overlapping longitudinal ioint construction is
required.

4.6 Protection ofkerbs, channels, etc

Kerbs, channels, guttering, manholes, guard rails, bridge railings and

other structures that may be soiled during spraying operations should
be properly prorected. The sheeting should be kept firmly in position
bV ioil, stones or adhesive tape in such manner that it will not lift or be
biown away during windy conditions but will keep the areas to be
protected fully covired. The use of paper bags, sand or other materials
ihoutd not be permitted in lieu of plastic sheeting'

4.7 Areas inaccessible to mechanical equipment

Areas inaccessible to mechanical equipment should be constructed as

specified in National Transport commission Specification 4310.

4.8 Dust control

dlmP
Any bypasses and construction roads should be kept watered and
auri"g ar surfacing operations and all dust removed from surfaces
before any binder, aggregate or slurry is applied'

4.9 Opening to traffic

The road should nor be opened to traffic until the binder has set
sufficiently to retain the aggregate.
is
The contractor should not allow any construction equipment, which
likelytocausedamageroverthecompletedsurfacetreatment'The
should be re-sponsible for determining when any surfacing is
"rrgit.",
to be opened to Public traffic.

l3
 5. PROCESS CONTROL

5.1 Tolerances

The usual requirements relating to the base on which the surfacing is

constructed should apply.

The binder distributor used to apply the bitumen-rubber should have a

valid certificate issued in terms of TMH2 - National standard for the
spraying performance of binder distributors, published by the CSIR.

With highly viscous binders the binder is less self-levelling than those
normally used in road construction. This can lead to surface
irregularity commonly called "tramlining or roping".

It is therefore required that the coefficient ofvariation (100S/f) of the

spray application calculated for 100 mm srrips of the spray bar length,
excluding the outer 3fi) mm on each side, should not exceed 12 per
cent. The testing procedure should be prescribed by the engineer.

The completed bituminous surfacing should be free of corrugations or

any other wave effect where depressions are preceded and followed by
humps or ridges no matter how small the distance between the top of
the hump to the bottom of the preceding or following depression.

The completed bituminous surfacing should be of uniform texture

without gaps or patches and be free from any loose aggregate or binder
spillage.

The edges of the completed bituminous surfacing should be continu-

ously true to line.

14
5.2 Testing

For the purpose of process control the following test prograrnme

should be adhered to:

Test Minimum Testing FrequencY

Mterids
Aggegdc for chips:
Godi"i One test every 250 m3
ACV One test every I 0(X) m3
Ftakiness One test every 250 m3
ALD One test every 250 m3
Biunn-rubber As prescribed in Manual6
Applic*ion rates Complete records to be kept of actud
measurements made of quantities of
materials applied and rates of
application

l5
ORDINARY MEMBERS

Akasia Road Surfacing (Pty) Ltd Concor Roads (Pty) Ltd

Bewloc (Pty) Ltd Engen Petroleum Ltd
Javseal (Pty) Ltd
It
Bill Maycock Surfaces (Pty) Ltd
Bitumen Construction Services (Pvt) Ltd More Asphalt
Blitz Asphalt (Pty) Ltd National Asphalt (Pty) Ltd
BP SA (Pty) Ltd Rand Roads
BSI (Pry) Ltd Road Binders (Pty) Ltd ItD-
Caltex Oil SA (Pty) Ltd Roadspan Surfaces (Pty) Ltd a
Colas Central (Pty) Ltd Rumdel Construction (Pty) Ltd
Colas East (Pty) Ltd Shell SA (Pty) Ltd ?)

Colas North (Pty) Ltd Spray Pave (Pty) Ltd

Colas SA (Pty) Ltd Zebra Bituminous Surfacing cc
Colas South (Pty) Ltd
(D

(!
O

ASSOCIATE MEMBERS o
AA Loudon & Partners Jeffares & Green Inc o
Alpha Stone and Readymix Keeve Steyn Inc
Bitutek Laboratory (Pty) Ltd Ready Mix Materials (Pty) Ltd a
BKS (Pty) Ltd The Synthetic Latex Co (Pty) Ltd
Bradford and Conning VKE Consulting Engineers (Pty) Ltd

AFFILIATE MEMBERS (D

Jabulani Road Conhactors cc

Salphalt (Pty) Ltd
(D
Tifflin Purchase & Associates
q
(!
0

Cover printed on recycled paper

Editing md production by Sharon Johnson Communications

REVOLWDMFY PBIMNG 8 @3