MACROSEAL
COLD MICROSURFACING,
A SOLUTION IN THE
MAINTENANCE OF ROADS
WITH HIGH LEVEL OF TRAFFIC
Author: Mr. Jesus Rincon
Technology Manager
Vietnam January2015
MACROSEAL
What is a cold asphalt microsurfacing ?
A thin asphalt mix (9 – 12 mm) manufactured and
applied at ambient temperature
It is an asphalt mix of:
Polymer modified asphalt emulsion,
Selected aggregates with 10-12 mm maximum size
Mineral filler
Water
Additives
Instead of breaking by evaporation (as slurry seal) there is
a chemical reaction. This means:
Fast curing time
Can be applied at night
Can be placed in thicker layers than slurry seal
MACROSEAL
Why is Micro-surfacing applied?
• Seal the surface
Reduce oxidation and aging
Avoids the infiltration of water
• Improves the surface characteristics
Improves tremendously the skid resistance
Corrects raveling and flushing
Correct minor irregularities (leveling) and
rutting.
MACROSEAL
Where is Micro-surfacing applied?
• On maintenance (asphalt and concrete):
As a preventive treatment
As a curative treatment
• On new roads
As a wearing course
As an interlayer
Microsurfacing is not to be applied as an
stand alone treatment when there are
structural defects !!!
MACROSEAL
Where is Micro-surfacing applied?
• Roads
Roadways
Shoulders
Ramps
Bridges
• Airfields
Taxiways and runways
• Streets
Roadways
Colored pavements
Bicycle paths
MACROSEAL
SPECIFICATIONS and TESTING
International Slurry Surfacing Association
(ISSA): A143 (2005) Recommended
Performance Guidelines for Micro-Surfacing
http://www.slurry.org/downloads/A143.pdf
ASTM: ASTM D 3910 and 6372-05 Standard
Practices for Design, Testing, and Construction
of Slurry and Microsurfacing, http://astm.org
Spanish’s Ministry of Public Works, Article 540
of the PG3 (2012).
MACROSEAL
SPECIFICATIONS and TESTING (II)
http://astm.org
http://www.slurry.org/downloads/A143.pdf
MACROSEAL
MATERIALS (I)
MACROSEAL
MATERIALS (II)
Asphalt Emulsion
Polymer modified cationic/quick set.
Percentage of bitumen: app: 60 %
Percentage of dry polymer: app: 2 %
pH of the emulsion must be close to 2.
The penetration of the bitumen used in the
manufacturing must be selected according to
the traffic and weather conditions of the area.
MACROSEAL
MATERIALS (III)
CHARACTERISTICS OF THE EMULSION FOR MICROSURFACING
Characteristic Unit ASTM Requirement
Viscosity, S.S.F, 25º C s D 244 > 20, < 150
Particle Charge D 244 Positive
Water Content % D 244 < 40
Residue asphalt
bitumen by evaporation
% D 244 > 62
5 days Settlement % D 244 < 10
Sieve Nº 20 (0.85 mm) % D 244 < 0.10
Residue by evaporation, ASTM 244
0.1
Penetration 25º,100g,5s
mm
D5 50 - 90
Ductility 5ºC: (5cm.min) cm D 113 > 10
Elastic recovery % D 6084 > 15
MACROSEAL
MATERIALS (IV)
Aggregates (ASTM C 117 and ASTM C 136) COARSE AGGREGATES
SIEVE (m CHARACTERISTIC ASTM Requirement
MS-1 MS-2 MS-3
m.)
Flakiness and elongation value D 4791 < 30
12.5 100
10.0 90-100 100 Wear “Los Angeles” C 131 < 25
8.0 77-92 90-100 100 Accelerated polishing coefficient D 3319 > 50
6.3 64-83 74-92 90-100
4.0 55-74 60-84 78-93 COMBINED AGGREGATES (Passing # 4)
2.0 35-55 40-64 60-80
Property Test Method Requirement
1.0 25-41 25-45 44-64
Sand Equivalent Value ASTM D 2419 > 65
0.50 15-30 15-31 30-48
0.25 9-20 10-22 19-33
It is also recommended to do the methylene blue
0.063 3-7 5-9 8-14
test on the fine aggregates according to the
standard NLT.-171/86 (Spanish standard). The
If traffic is high (100-200 heavy v./d), result must be lower than 1.
aggregates must be 100% crushed from the
quarry with more than two broken faces.
Less than 100, the crushing value > 90
MACROSEAL
MATERIALS (V)
• Mineral Filler (Cement). Mineral filler shall be either
ordinary Portland cement (recommended), lime stone dust or
hydrated lime, compatible with the emulsion according to the
mix design. It is necessary to start the breaking of the
emulsion and to get the final consistency.
• Water. The water shall be potable, free from harmful salts
and contaminants. Water is needed to get the final consistency
of the mix and to lubricate the aggregates avoiding the
premature setting of the emulsion
• Additive. In most of the cases, some additives are required
to adjust the setting time of the emulsion. This time depends
on the weather conditions, constituents of the mix and can
change during the daytime.
MACROSEAL
MIX DESIGN (I)
CRITERIAS FOR THE MIX DESIGN
TYPE OF MICROSURFACING
CHARACTERISTIC
MS1 MS2 MS3
Dry Average dosage (kg/m2)
12.0 – 15.0 9.0 – 12.0 7.0 – 9.0
(without water)
Layer in which it is applied (*) 1st, 2nd or Unique 1st or Unique
Residual bitumen (% w/aggreg.) 5.0 - 7.0 6.0 - 8.0 6.5 - 9.0
Application, Type of Traffic H, M and L L, and shoulders
TYPE OF HEAVY TRAFFIC
TEST H M L
Wet Track Abrasion Loss (ASTM D 3910) (g/m2) < 350 <450 <550
Wet Cohesion at 60m (ASTM D 3910) (kg.cm) >20
Type of traffic:
H = Roads with Heavy traffic mostly.
L = Roads with Light traffic mostly.
M = Roads with Mixed heavy and light traffic.
MACROSEAL
MIX DESIGN (II)
More important tests:
• Mixing (Breaking time)
• Abrasion (% minimum binder)
• Cohesion (opening to the traffic)
Other test:
• Wheel load test (% maximum binder)
MACROSEAL
LABORATORY EQUIPMENT (I)
MIXING TEST
• Beaker
• Glass rod
• Tray
It gives information
about the cohesion,
consistency, breaking
time, curing time, etc.
MACROSEAL
LABORATORY EQUIPMENT (II)
Cohesion tester
It gives information about type of mix an traffic opening time
MACROSEAL
LABORATORY EQUIPMENT (III)
Wet Track Abrasion Test (WTAT)
It gives information about the minimum amount of binder in the mix
MACROSEAL
LABORATORY EQUIPMENT (IV)
Load Wheel Tester (LWT)
It gives information about the maximum amount of binder in the mix
MACROSEAL
MIX DESIGN (III)
MACROSEAL
MANUFACTURING MACHINERY (I)
MACROSEAL
COLD MICROSURFACING MACHINE DESCRIPTION
Water Aggregates Cement
tank hopper hopper
Spreader
box
Additive
Mixer
Emulsion tank
tank
MACROSEAL
COLD MICROSURFACING MIXER
Twin axle
Triangular mixer
paddles
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Empty Working
Spreader box
MACROSEAL
MANUFACTURING MACHINERY (II)
MACROSEAL
APPLICATION (I)
Pavements with superficial problems and good bearing
capacity.
To recovery the original surface characteristics of the
pavement.
• Waterproofs the surface (it helps but does not solve the
crack problems).
• Rejuvenates the mix and the surface.
• Protect the pavement.
• More durability of the surface.
• Increase the skid resistance of the pavement.
MACROSEAL
APPLICATION (II)
TYPE OF APPLICATION MAX. AGG. SIZE AVERAGE RATE
2
Streets of the city < 6 mm. 8-12 Kg/m
Highway, dual carriageway < 8 – 10 mm. 12-16 Kg/m2
2
Airports 3-5 mm. 6 – 9 Kg/m
LAYER APPLICATION
• Microsurfacing is applied in one or two layers.
• In very polished surface is always advisable to apply
the product in two layers.
• In the case of multiple layers, the first one should have
smaller aggregates size and must have some days open
the traffic between the first and the second one.
MACROSEAL
APPLICATION (III)
STEPS TO MAKE A GOOD APPLICATION
1. LABORATORY MIX DESIGN AND JOB MIX FORMULA
(Approval by the Engineer).
2. SURFACE PREPARATION: Potholes, cracks, deformations,
cleaning, etc.
3. TACK COAT: If it is required.
4. CALIBRATION OF THE MACHINE AND TRIAL (Approval
by the Engineer).
5. APPLICATION of Microsurfacing on the road (One or two
layers).
6. COMPACTION. If it is required
7. QUALITY CONTROL. In the laboratory for materials and mix.
8. SWEEPING the road surface (next day)
MACROSEAL
APPLICATION LIMITATIONS
• Temperature: It shall no be applied when is < at
10ºC . No apply it when is expected a freezing in the
next 24 hours.
• Rain: Do not do it with rain (It could wash the
emulsion).
• Wind: It is favourable for the curing.
• Humidity: Low humidity is favourable.
• Weather conditions: When it prolongs opening to
traffic a reasonable time.
MACROSEAL
ADVANTAGES (I)
1. SMALL THICKNESS Maximum size of the
aggregate.
2. CONTROLLED OPENING TO THE TRAFFIC.
Controversial points of traffic; intersections, airports,
etc.
3. ADAPTATION TO THE WORK CONDITIONS.
Thanks to the emulsifiers and additives.
4. EASY APPLICATION AND HIGH DAILY
PRODUCTION. 10.000 m2/day.
MACROSEAL
ADVANTAGES (II)
5. LOW THERMIC SUSCEPTIBILITY (Because the
polymer and then, more Durability, more economical).
6. HIGH ELASTICITY (Latex) (Better performance,
then more durability, then more economical).
7. HIGH ROUGHNESS AND TEXTURE. (Better high
skid resistant, then safer pavement)
8. HIGH DURABILITY. Thanks to the use of polymers.
MACROSEAL
ADVANTAGES (III)
9. GOOD ASPECT AND FINISHING. More
comfortable surfaces.
10. ENERGY SAVING. Because microsurfacing is a cold
techniques, using asphalt emulsion as binders. More
economical
11. AMICABLE WITH THE ENVIRONMENT. No
fluxants or solvents. More economical
MACROSEAL
ADVANTAGES (IV)
According to its characteristics:
High Roughness and Texture: Safety.
High durability and energy saving:
Economy.
Good looking and appearance: Comfort.
MACROSEAL
QUALITY CONTROL
1. STOCKPILES. It has to be checked the gradation of the
aggregates, single sizes. Other properties that Engineer
consider; Sand Equivalent, abrasion, etc.
2. JOB SITE. Check the quality of the microsurfacing mix:
extraction to get the residual asphalt content, gradation of
the recovery aggregates, the application rate of the mix
(Kg/m2), consumption of the materials. Etc.
3. ON THE ROAD. Superficial macrotexture obtained
according to the test ASTM E 965, Sand patch test, and
carried out before open to traffic should be within 0.6- l.1
depending the type of gradation used.
MACROSEAL
QUALITY CONTROL (II)
ASTM E 965, Sand patch test
MACROSEAL
ELSAMEX EXPERIENCE
STARTED THE DEVELOPMENT OF THE MICROSURFACING
TECHNOLOGY IN 1983 AT ITS RESEARCH CENTER OF MADRID.
THE DEVELOPED COLD MICROSURFACING SYSTEM BY ELSAMEX
WAS CALLED MACROSEAL ®
STARTED THE WORK APPLICATION ON ROADS IN 1986 IN SPAIN.
HAS TRANSFERRED THE MACROSEAL TECHNOLOGY TO 37
COUNTRIES, APPLAYING MORE THAN 25 MILLION OF SQUARE
METERS EVERY YEARS, (USUALLY TO PRIVATE COMPANIES)
WITH DIFFERENT;
• ECONOMY: USA and NEPAL.
• MATERIALS: EGYPT and FRANCE.
• CLIMATOLOGY: NORWAY and MOROCCO.
• SKILL PERSONNEL GRADE: DENMARK and NIGERIA.
• CULTURE: THAILAND and ARGENTINA.
• INFRAESTRUCTURES: (Highway, Secondary roads, airports,
streets, etc).
IT IS EASY ITS IMPLEMENTATION
MACROSEAL
COLD MICROSURFACING
FRESH MIX
MACROSEAL
COLD MICROSURFACING
NEW AND OLD
SURFACES
MACROSEAL
COLD MICROSURFACING
MOTORWAY
ITALY
MACROSEAL
COLD MICROSURFACING
EXPRESS ROAD
SPAIN
MACROSEAL
COLD MICROSURFACING
EXPRESSWAY
SPAIN
MACROSEAL
COLD MICROSURFACING
TOLLWAY SPAIN
MACROSEAL
COLD MICROSURFACING
EXPRESSWAY
INDIA
MACROSEAL
COLD MICROSURFACING
EXPRESSWAY
TURKEY
MACROSEAL
COLD MICROSURFACING
AIRPORTS
SPAIN
MACROSEAL
COLD MICROSURFACING
HIGHWAY
CHINA
MACROSEAL
COLD MICROSURFACING
ROADS
MOROCCO
MACROSEAL
COST ECO – EFFICIENCY ANALISYS (I)
DIFFERENCES (MICROSURFACING-HAM)
CHARACTERISTIC MICROS HAM
Thickness 1 cm 4-5 cm
Surface Durability (6-8 years) (8-10 years)
Cohesion (traffic) 1.5 Hours 2.5 Hours
Machinery Travel type Fix plant
Tack coat NO YES
Compaction NO YES
Daily Production 12,000m2 8 -10,000m2
Skid resistance Much higher Less
Plasticity interval Higher Less
Bearing capacity NO YES
To adapt to work conditions YES NO
Energy saving YES NO
MICROS = COLD ASPHALT MICROSURFACING
HAM = HOT ASPHALT MIX (CONVENTIONAL)
MACROSEAL
COST ECO – EFFICIENCY ANALISYS (II)
HOT ASPHALT COLD MICROS.
CHARACTERISTICS (%)
(5 cm thick) (13kg/m2)
Approx. Cost (USD) per lane km/year 3,000 1600 53.3
Approx. Cost (USD) per m2 8,5 3,5 41.2
Life span (years) 10 8 80
Materials (tons/ lane km/ year) 45,625 5,931 13.0
Fuel consumption (kg/ton) 8 1 12.5
Fuel consumption (kg/lane km/year) 365 5,93 1.6
CO2 emission (Kg/lane km/year) 1,078 5 0.5
NO2 emission (Kg/lane km/year) 5.1 1.3 25.5
Accidents (estimated ratio) 1.0 0.33 33
Health risk (estimated ratio) 1.0 0.25 25
( Width of the lane 3,65m) 1 USD = 0.87€
MACROSEAL
COST ECO – EFFICIENCY ANALISYS (III)
ENERGY
100
80
60
40
MATERIALS EMISSIONS
20
ACCIDENTS HEALTH
HAM MSF
Environmental-Footprints
MACROSEAL
COST ECO – EFFICIENCY ANALISYS (IV)
CONCLUSIONS
The current study on Cost-Eco-efficiency analysis of
preventive maintenance demonstrates that microsurfacing
is more Cost-Eco-Efficient than hot asphalt mix overlay
(reinforcement), due to:
1. Lower cost per square meter and lane km per year.
2. Lower consumption and transportation of the raw
materials.
3. Lower consumption of fuel (energy savings) in the
application.
4. Lower emission to the atmosphere of polluting products.
5. Lower risk of accidents on the road and health problems.
MACROSEAL
MACROSEAL
THANK YOU
VERY MUCH
FOR YOUR
ATTENTION.
