BITUMINOUS
COATINGS
WHEN AND HOW TO USE THEM
Beyond its widespread use for
road paving, bituminous coatings
are used in many industries to
prevent corrosion of metallic
substrates. This guide examines
bitumen, the raw material used to
manufacture bituminous coatings,
the history of bituminous coatings,
and common applications. It also
covers the substrate preparation
steps that are required before
applying this type of coating.
WHAT IS BITUMEN?
Bitumen, also known as asphalt in the United States, refers to a naturally occurring organic
material consisting primarily of carbon and hydrogen. This compound can also contain
traces of other elements, such as nitrogen, sulfur, oxygen, iron and alumina. In Europe,
bitumen refers to the pure form of the hydrocarbon material, while asphalt is used to
describe its raw form.
For the purposes of this article, the American Society for Testing and Materials (ASTM)
definition will be used. In their publication, “Standard Terminology Relating to Roofing and
Waterproofing,” the ASTM defines bitumen as:
A class of amorphous black or dark colored (solid, semi-solid, or
→ viscous) cementitious substances, natural or manufactured, composed
principally of high molecular weight hydrocarbons, soluble in carbon
disulfide, and found in asphalts, tars, pitches, and asphaltites; or,
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→ A generic term used to denote any material
composed principally of bitumen.
On the other hand, the ASTM defines asphalt as “A dark brown to black cementitious
material in which the predominating constituents are bitumens which occur in nature or
are obtained in petroleum processing.” While the term has been previously used to refer to
natural mineral deposits (e.g., from asphalt lakes), most of the bitumen used in the United
States comes from petroleum processing.
Physically, bitumen is a thick, black, sticky substance. In its liquid to semi-solid form, it
has a viscosity that is similar to that of molasses at room temperature. Like almost all
hydrocarbons, bitumen does not mix with water (i.e., it is hydrophobic). This attribute
makes bitumen a popular component in water-resistant paints and coatings.
Most processed bitumen (over 70%) is used in roadway construction. When mixed with
other materials, bitumen acts as a binder in the production of asphalt concrete. The
remaining 30% is primarily used for waterproofing, sealing and insulating applications.
HISTORY OF BITUMINOUS
COATINGS
Bitumen is one of the oldest known engineering
materials. The adhesive and waterproofing attributes of
this compound have been known for some time. As far
back as 5000 to 4000 BC, natural bitumen was used for
waterproofing by the Indus Valley Civilization in Mehrgarh.
Crop storage baskets and other containers were lined with
naturally occurring bitumen deposits.
In the same area, around 3000 to 2000 BC, bitumen was
used to line and waterproof the Great Bath, Mohenjo-Daro. Other historical accounts
of various civilizations, from ancient Egyptians to Sumerians, show that bitumen was
instrumental for numerous construction applications including bricklaying and shipbuilding.
In the modern world, the waterproofing quality of bituminous coatings is used to protect
essential structures and infrastructure, much in the same way they were used for several
millennia.
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In the early to mid-20th century, most of the bitumen used in the United States originated
from Trinidad and Tobago asphalt lakes and Mexican crude oil. Today, bitumen and
asphalts are obtained from either natural deposits in limestone or sandstone rock
formations (natural bitumen), or colloidally dispersed hydrocarbons in crude oil processing
(artificial bitumen).
Artificial bitumen is further classified into three major groups:
Oil or petroleum asphalts - These are pure bitumens possessing high
1 solubility in carbon disulfide. They are produced via the steam distillation
or vacuum distillation of crude oils containing high quantities of asphalt.
2 Cracked asphalts - Cracked asphalts are also derived from petroleum.
They are produced as a by-product of oil-cracking processes.
3 Coal tar - Coal tar is a thick dark liquid obtained as a by-product from the
processing of petroleum, oil-shale, coal, wood and other organic materials.
APPLICATIONS FOR
BITUMINOUS COATINGS
While the uses of bituminous coatings are varied, they all serve the same basic purpose
– protection. Bituminous coatings are classified mainly by the industry in which they are
used. These include:
◉◉ Specialty paints and coatings industry – Here, bituminous coatings are used to protect
metallic surfaces from the air and moisture that can result in oxidation and corrosion.
◉◉ The roofing industry – Asphalt coatings are used to line and weatherproof various
roofing elements.
◉◉ The construction industry – Concrete elements and mortar joints are commonly
waterproofed and protected with bitumen-based coatings.
◉◉ The paving industry – In addition to waterproofing protection, bitumen is used as an
adhesive to bind together the various elements of asphaltic concrete in roads and
highways.
The following sections delve into the applications for bituminous coatings.
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SPECIALTY PAINTS AND COATINGS
Due to their unique characteristics, bitumen and other bitumen-derived products are
employed in several specialty coating applications. One of the predominant uses of
bitumen-based coatings is in the pipe and automotive coating industry. Bituminous
coatings are also used as containment coatings (i.e., coatings that are capable of
containing leaks and spills) in many industrial settings.
In piping systems, bitumen-based coatings are combined with a thermosetting resin to
create an impervious barrier on the interior of the pipe. This helps prevent the intrusion
of groundwater from the surrounding soil; thus mitigating corrosion and rusting. The
additional cost of using bituminous coatings in underground piping is offset by the
potentially large expense of pipe remediation and replacement.
In the automotive industry, bituminous coatings are primarily used to rustproof the
underbodies of vehicles. These coatings are typically modified with several additives that
give the coating additional flexibility and adhesion when applied to metallic parts. While
coal tar was once the predominant material used for automotive underbody coatings,
petroleum asphalts have taken its place. Because they tend to be stiffer than coal tars,
petroleum asphalts are combined with plasticizers, such as phthalate or butyl benzyl
phthalate to liquefy the coating and increase its workability.
Bituminous paints and coatings are also commonly used in specialty coatings to seal
structures from soil exposure. These coatings are frequently applied to retaining walls,
ponds, dams and levees to prevent potentially damaging water seepage. On sheet metals,
bituminous paints can also provide sound deadening and absorption effects.
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ROOF COATINGS
Bitumen has been an essential roofing material
since the turn of the 20th century. Roof
construction in most modern residential and
commercial buildings involves bitumen products
in one form or another. A common roofing system,
built-up-roofing (BUR), consists of alternating
layers of asphalt or polymer-modified asphalt and
a reinforcing membrane.
In the past, hot-melt asphalt, which involved
heating the material up to 450°F (232°C) using
a hot kettle, was extensively used. Once the
asphalt coating reached the desired viscosity, it
was applied evenly to the roofing structure. Due to the inherent dangers associated with
hot-melt applications, the roofing industry has now moved towards cold-applied systems.
In cold-applied systems, the asphalt is modified with solvents, fillers, thixotropes and other
various additives. These compounds improve the flow, workability and strength of the
bituminous material, allowing it to be applied to the roofing at ambient temperatures. When
dried, the coating forms an impervious waterproofing membrane.
The quantity and type of volatile solvents in the coatings are varied to control the cure
times. These compounds, also known as cutbacks, generally consist of spirits and
naphthas that serve to cut or solubilize the asphalt.
Asbestos was once commonly used as a thixotropic and reinforcement additive in many
bituminous roof coatings. However, the health risks associated with asbestos has created
a push towards asbestos-free coating substances. Modern roofing coatings now use
cellulose, synthetics and glass fibers as reinforcement
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WATERPROOFING MEMBRANES
Waterproofing membranes are thin layers of material laid over a surface to prevent the
passage of water through it. Bitumen-based membranes are employed extensively in the
construction industry to help protect vital structural elements. In building construction,
poured or cast concrete elements are inherently porous, which can encourage water
seepage. Prestressed concrete members, foundations, retaining walls and roof decks
in residential and commercial buildings are just some of the structural elements where
waterproofing membranes are used.
These membranes are generally composed of bitumen contained within an elastomeric
polymer matrix. The types of bitumens commonly used in this application are coal tar
and petroleum asphalts, while the polymer matrix usually consists of various aromatic
polyurethanes.
In addition to concrete elements, structural steel and steel reinforcing bars also benefit
from the use of bituminous coatings. In these applications, coal tar is typically the coating
of choice. Similar to their role in pipe coatings, coal tars act as a barrier between the steel
and the atmosphere. This prevents air and moisture from coming into contact with the
substrate; thus preventing rebar corrosion. The composition of these types of coatings can
be configured to meet the requirements of the particular steel coating application.
As with other bituminous coating applications, aromatic coal tars are gradually being
replaced by petroleum asphalts due to environmental concerns. While epoxy powder
coatings and polyethylene dip-coated systems are also used extensively, relatively
inexpensive bitumen-based coatings remain a popular rebar coating option.
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ROAD PAVING
The road paving industry accounts for the most significant consumption of bitumen and
bitumen-based coatings. Road paving is also known as one of the oldest uses of this
material. Hot asphalt cutbacks, also known as road oils, have traditionally been used as
solvents to seal roads and coat aggregates for roadway applications.
In the modern paving industry, asphalt emulsions are used primarily to prime new paving
surfaces and repair worn or damaged areas. These chemically stabilized emulsions
are usually prepared in advance and combined with the aggregate on site. In this case,
asphalt heating is not required, thus, making asphalt emulsions easier to work with than
hot mix paving.
Bitumen-based paving sealers are commonly used in asphalt driveways and parking lots
to protect the driving surface from the adverse effects of weather exposure. Coal tar is
generally used for this purpose due to its resistance to gas, oil and other hydrocarbon-
based products. While asphalt sealers are also a viable option, they must first be modified
with latex or polymer additives to increase their solvent resistance.
For the repair of minor damage to road surfaces, other types of bituminous coatings,
such as slurry seals and micro surfacing are used. These compounds contain either latex
or polymer-modified asphalts combined with fine aggregate filler material. Coal tar is
generally not used to repair roads due to its relatively low coefficient of friction (i.e., the
coating produces a surface that is too slippery). Tack coats with asphalt cutbacks are also
frequently used when binding together various asphalt layers.
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SURFACE PREPARATION FOR
BITUMINOUS COATINGS
With the exception of road paving, the application of bituminous coatings involves
careful planning and preparation of the substrate surface. Regardless of the structure
(walls, foundations, roofing, etc.), the condition of the surface plays a vital role in the
effectiveness and performance of the coating.
Prior to applying bituminous paints or coatings, the surface should be relatively clean and
free of unwanted materials, such as dirt, oil, grease, rust, mill scale, etc. For previously
coated surfaces, loose or blistered paints should be also be removed.
On metallic surfaces where rusting may occur, cleaning can be performed using wire
brushes or sandpaper. For larger surfaces, blast cleaning methods, sanding machines, or
other mechanical methods can be used. Harsh conditions, such as those found in marine
environments, may require additional protection using anti-corrosive primers. Similar cleaning
and surface preparation techniques can also be used for wood and concrete surfaces as well.
Any residual dust that may be present after cleaning should be removed using
compressed air before applying the first coat of bituminous paints or coatings.
CONCLUSION
Bituminous coatings are used extensively in a wide variety of applications and
industries. While they have been in use for several thousands of years, their
use as an engineering material continues to increase. New technologies and
advancements have created new applications for this age-old engineering material
in modern industries.
All bitumen, however, are not created equal. Natural bitumen and artificial
bitumen, which are further classified into petroleum asphalts, cracked asphalts
and coal tar, all possess unique physical, mechanical and chemical attributes that
lend themselves to numerous applications.
Despite their various characteristics, all bituminous paints and coatings serve
the same primary purpose – to protect the coated surface. Their durability and
waterproofing properties help to seal crucial elements from potentially damaging
moisture ingress and increase the longevity of the surface under consideration.
