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RPF 9 MAY 2007TECHNOLOGY IN PRACTICE
FEEDBACK ON CUTBACKSPECIFICATIONS
Presentation by Johan Muller,
Acknowledgement: Trevor Distin, Mike Zacharias, Daniel MashatolaHannes Lambert, Pieter Goosen, Desmond O’Brien, Kobus Louw, Dennis Rossmann, Jacques van HeerdenDenzil Sadler,
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PRIME PROBLEM?
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POSSIBLE AMENDMENTS
• PROBLEM STATEMENT:
• OVERCOME PROBLEMS WITH MC30– LACK OF PENETRATION– SLOW CURING (UP TO 7 DAYS)
• PARTICULARLY INLAND
• PARTICULARLY WINTERTIME
• PARTICULARLY DENSE G1
• PARTICULARLY CEMENT STABILISED
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HISTORY & BACKGROUND
SABS 308:1971
• Never amended since 1971
• Requirements and product range limited
• RC 250 no longer available ex refineries
• Invert Bitumen Emulsion (no SANS spec?)
• Tar primes discontinued in 2006
• Emulsion primes recent addition
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WHAT IS HAPPENING?
USE OF TAR PRIMES DISCONTINUED• Sabita seminars held in September 2006
– Use of Tar to be discontinued– Sabita Manual 26 launched November 2006
• Sasol CarboTar closed shop 30 June 2006• Mittal limited tar products still availableCUTBACKS• MC grades available from Refineries• IBE manufactured by Secondary Suppliers• Emulsion primes promoted based on quick
drying ability
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CUTBACK BITUMEN PRIMES
• MC 30 – Works OK in summer– Poor penetration in winter – Poor penetration on dense / stabilised bases
• MC 30 + 10% IP penetrates better• Invert bitumen emulsion penetrates better
– Expensive cutter – kerosene = Jet Fuel
• MC70 – Hardly ever used.
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CUTBACK BITUMENS
• MC3000– Necessary for use in sand seals– Used in Otta Seals in wintertime
• MC 800 – Limited use in specialised cold mix
applications
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COMPARISON OF AVAILABLE PRIME PRODUCTS
• MC30 – 55% residual bitumen– 45% kerosene
• IBE Invert bitumen emulsion– 85% MC30 / IP (41,25% residual bitumen)– 15% water - emulsifier assists penetration
• Emulsion prime = MC30 + IP + water– 40% water– 60% MC30 + IP = <30% residual bitumen
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WHAT DID WE DO?
• R&D indicates a new type of prime required– Performance verified on laboratory scale– Field trials were performed– Specification is now required
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Invert Bitumen Emulsions
VS
LOW VISCOSITY CUTBACK PRIME
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DENSE BASES PREPARED
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PRIMES APPLIED
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MC 30 IBE
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Emulsion Primes
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Research & Development
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MC 30 PERFORMANCE VARIABLE
Poor penetration / takes long to dry
Why?• Non polar components – no surface charge
to assist with capillary actions• Bases too wet – PI too high• Base too dense• Viscosity of prime too viscous• How to overcome?
– MC30 (possibly by reducing viscosity)
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Research & Development
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Research & Development
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Research & Development
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Emulsion Primes
Emulsion prime 2Emulsion prime 1
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What influences penetration performance?
• Viscosity is temperature related– Lower temperature = higher viscosity
• Viscosity affect– High viscosity = poor penetration
• Temperature affect– Low temperature = poor penetration
• Surface– Dense surface = poorer penetration
• Moisture content– Water fill voids and prime lies on top
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What influences drying performance?
• Amount of penetration• Type of cutter (fluxing fluid)• Temperature
– Higher temperature = higher rate of evaporation of cutter
• Moisture– Excessive water fills air voids– Water polar and cutter non polar organic components does
not mix
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The Viscosity - Temperature Relationship for MC 30 Cutback Bitumen
0
1000
2000
3000
4000
5000
6000
0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0 50.0 55.0 60.0
Temperature (°C)
Visc
osity
(mPa
.s)
Temperature-Viscosity relationship for MC30
MC 30
MC 10
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Research & DevelopmentROAD TEMPERATURES/ TIME RELATIONSHIP (SUN)
0
5
10
15
20
25
30
35
40
45
07:00 08:00 09:00 10:00 11:00 12:00 13:00 14:00 15:00 16:00
TIME
TE
MP
ER
AT
UR
E
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Difference between road & air temperatures(sun & shade conditions)
Daytime Temperature Profile for 11/08/06
0
5
10
15
20
25
30
35
08H00 09H00 10H00 11H00 12H00 13H00 14H00 15H00Time
Tem
per
atu
re (
°C)
SHADE AIR TEMP
SHADE ROAD TEMP.
SUN AIR TEMP.
SUN ROAD TEMP.
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What effect does rain & clouds have?Daytime Temperature Profile on 01/12/06
0
5
10
15
20
25
30
35
40
45
08H00 09H00 10H00 11H00 12H00 13H00 14H00 15H00 16H00
Time
Tem
per
atu
re (
°C)
SHADE AIR TEMP
SHADE ROAD TEMP.
SUN AIR TEMP.
SUN ROAD TEMP.
WIND RAIN
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Monthly Average TemperaturesAverage Temperature Variation during OCTOBER 2006
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
45.0
50.0
AIR SHADE
08:00
09:00
10:00
11:00
12:00
13:00
14:00
15:00
16:00
ROAD SHADE
08:00
09:00
10:00
11:00
12:00
13:00
14:00
15:00
16:00AIR SUN
08:00
09:00
10:00
11:00
12:00
13:00
14:00
15:00
16:00
ROAD SUN
08:00
09:00
10:00
11:00
12:00
13:00
14:00
15:00
Time
Tem
per
atu
re (
°C)
min
max
average
AIR AIR
ROADROAD
SHADE
SUN
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CUTBACK ALTERNATIVES
TWO CUTBACK OPTIONS
1) MC30 + 10-15% IP on site blending – discourage practice (HSE)
2) MC10 ~ MC30 + more cutter ex REFINERIES– Quality assurance excellent– Safer / controlled production environment
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ONE OPTION STANDS OUT
• MC 10 REPLACING MC30• Australians ID same requirement
(AMC00)• MANUFACTURED BY REFINERIES• AMEND SANS 308 (SLOW PROCESS)• CUSTOMER REQUIREMENT
– BUY– SUPPLY– APPLY
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IMPLICATIONS OF PRODUCT
NO COMPROMISES
• ENVIRONMENT – AP-R153– No effect on OZONE depletion– Heating cutbacks does not contribute to
GREENHOUSE GASSES– SMOG in urban areas?– Contribution to AIR POLLUTION SMALL
• Worker Safety• Refineries• Handling & Application
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WAY FORWARD?
• Does RPF agree that TASK TEAM BE FORMED?
THEN• PROPOSAL
– NEW SPEC LOW VISCOSITY PRIME• Viscosity at ambient (25°C)• Remove penetration test requirement on residue
– REVISE SANS 308 (1971)– INCLUDE BITUMEN PRECOATING FLUIDS