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Advanced Sealcoating

Advanced Sealcoating. NPE, FEB 1, 2007, NASVILLE, TN TOPIC HOW TO IMPROVE THE PERFORMANCE OF YOUR SEALER Sealer Composition Mix Designs Coverage Rates, Film Thickness Optimum Cure & Film Formation Presented by Girish Dubey President, STAR, Inc. DESIGNED FOR SEALCOATING PROFESSIONALS.

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Advanced Sealcoating

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  1. Advanced Sealcoating NPE, FEB 1, 2007, NASVILLE, TN TOPIC HOW TO IMPROVE THE PERFORMANCE OF YOUR SEALER Sealer Composition Mix Designs Coverage Rates, Film Thickness Optimum Cure & Film Formation Presented by Girish DubeyPresident, STAR, Inc.

  2. DESIGNED FORSEALCOATING PROFESSIONALS WHO WANT TO LEARN BEYOND THE BASICS OF SEALCOATINGS. TO MAKE EVERY JOB LOOK & PERFORM THE VERY BEST. PERFORMANCE IS THE CENTERPIECE

  3. PERFORMANCE THE CENTERPIECE These facts are applicable to most water based coatings. All are very critical. • GOOD QUALITY SEALER- Meets specifications, and has an established track record. • RIGHT MIX DESIGN- Follow recommendations (manufacturer or job specs.). • APPLY @ RECOMMENDED RATES- To deposit the right amount of sealer on the pavement. • DRY & CURE UNDER RIGHT AMBIENT CONDITIONS- temperature, humidity, wind velocity.

  4. SEALCOATING BASICS SEALCOATINGS ARE ; • WATER-BASED COATINGS, A STABLE DISPERSIONS OF; a. BINDER (RT-12 or AC)is the backbone of the sealer and provides the protection to the pavement against the elements.- weather, salt, water, chemicals, etc. b. Clay and Fillers- Provide tensile strength, toughness, body and stability. c. Water- is the medium in which tar, clay fillers are dispersed. d. Emulsifiers, specialty chemicals- help dispersion, provide stability and special properties.

  5. What Makes A Good SealerHow Can You Tell? 1. Meets /or Exceeds Specifications: (ASTM, FEDERAL, FAA, etc.). 2. Proven Performance: Good Track Record. 3. Dark, Chocolate Brown in Color- Indicating Fine Dispersion of Tar or AC. 4. pH - 7-8 - Below 7 slightly acidic- May be unstable, - Over 8- Alkaline- Prone to water sensitivity. 5. References, Comparative Evaluation

  6. What Makes A Good SealerHow Can You Tell? 4. pH of the sealer, 7-8: Lower Ph-slightly Acidic may induce instability. Higher pH-Alkaline- Prone to water sensitivity. 5. References, Comparative Test Data.

  7. TYPICAL SEALER COMPOSITION Undiluted (as manufactured)

  8. MIX DESIGNSAN OVERVIEW. SEALCOATING IS NEVER APPLIED IN ITS CONCENTRATED FORM GENERALLY MIXED WITH; 1. WATER - FOR FLUIDITY, WORKABILITY, 2. SILICA SAND - TEXTURING, - TRACTION, - FILLING VOIDS (profile, minor surface cracks), 3. ADDITIVES (OPTIONAL) - PERFORMANCE BOOSTING (Flexibility, Toughness, Resistance to salt, water, chemicals..), - Drying Accelerator

  9. MIX DESIGNSAN OVERVIEW. STANDARD SYSTEM: A 2-coat system Mix DesignSEALCOATING (CONC) 100 GAL WATER (30% BY VOL.) 30 GALSILICA SAND /aggregate 200-300 lb TOTAL 145 GAL.Application Rates, Gal (conc.) Sealer/Sq. Yard: Ist. Coat- 0.10-0.12 IInd. Coat- 0.08-0.10 TOTAL (2 COATS) : 0.18-0.20 GAL. /SQ. YARD.

  10. MIX DESIGNS

  11. Hazards in Altering the Mix Designs Follow the recommended mix designs Changing the mix design may cause performance problems 1. WATER: A. EXCESSIVE- - Thinner Dry Film Thickness (D.F.T.) - Poor Durability, - Premature failure. Important ADJUST APPLICATION RATE TO MAINTAIN DRY FILM THICKNESS. B. NOT ENOUGH WATER- - Poor Flow, uneven appearance - The sealer may not wet out the surface properly for good adhesion. - Tracking is possible.

  12. Hazards in Altering the Mix Designs The coverage rate will have to be adjusted to account for the higher amounts of water to maintain the same Dry Film Thickness (DFT)

  13. Hazards in Altering the Mix Designs 2. SAND/ AGGREGATE EXCESSIVE (OVER 5,6 LB)- POOR FLEXIBILITY, BRITTLENSS POOR ADHESION TO PAVEMENT POOR ANCHORING,SAND ROLL OUT PREMATURE FAILURE NONE OR VERY LITTLE (<1 LB) REDUCED TRACTION/SKID RESISTANCE UNEVEN TEXTURE AND APPEARANCE SOFT SHEEN (REFLECTANCE) PAVEMENT VOIDS NOT FILLED

  14. Hazards in Altering the Mix Designs 3. ADDITIVES - VERY SELECTIVE. - FOLLOW MANUFACTURER’S RECOMMENDATIONS. - MAY NOT BE COMPATIBLE WTH THE SEALER. EXCESSIVE (OVER 5 %): - WASTE OF MONEY - MAY ADVERSELY AFFECT PROPERTIES NOT ENOUGH (LESS THAN 1 %): - INEFFECTIVE - MARGINAL PERFORMANCE IMPROVEMENT, - MOSTLY FOR NAMESAKE.

  15. COVERAGE RATESAREA COVERED BY A GALLON OF (undiluted) SEALER EXPRESSED IN 2 WAYS; 1. Gallonsof sealer per square yard (gal./sq. yard) .Most commonly used. or 2. Square feet area covered by one gallon of undiluted sealer. A typical Coverage Rate for a two (2) coat application is- 0.18-0.20 gal (undiluted) sealer/sq. yard 1st Coat- 0.10-0.12 gal./sq. yd. 2nd Coat-0.08-0.10 gal./sq. yd.

  16. CRITICAL FACTORSFOR SEALER PERORMANCE COVERAGE RATE Sealer must be applied at the recommended coverage rate. It is assured by measuring: -WET FILM THICKNESS (W.F.T.) & -Calculating DRY FILM THICKNESS (D.F.T.) 2. CURE CONDITIONS: Must be right. TEMPERATURE(ground and surface) HUMIDITY OR RELATIVE HUMIDITY(R.H.)- Capacity of air to hold water @ ambient temperature. WIND VELOCITY

  17. COVERAGE RATECONFIRMATION-SEALER FILM THICKNESS STEP 1 DETERMINE THE WET FILM THICKNESS (W.F.T.) Two methods: Calculate-Apply sealer on a known area (sq. feet) and divide gallons used, to get coverage in sq. ft./gallon. W.F.T. (IN MILS) = 1604/COVERAGE IN SQ.FT.GALLON. Discussed later. . Use a wet film thickness gauge

  18. COVERAGE RATECONFIRMATION-SEALER FILM THICKNESSSTEP-2Determine the solids % by Volume 2. Calculate % solids by volume Water (% by Vol.) = 101.2/155.9 = 65% Solids (% by Vol.) = 100% - 65% = 35%

  19. COVERAGE RATE CONFIRMATION-SEALER FILM THICKNESS Step-3 Determine the wet film thickness Wet Film Thickness is expressed in mils 1 MIL= 1/1000 inch. IF THE ; a. COVERAGE IS KNOWN IN SQ. Ft./GAL. DIVIDE INTO 1604 (CONSTANT) For example for 50 sq. ft/gal., W.F.T. = 1604/50 = 32 MILS. 1604 = one gallon of coating covers 1604 sq. ft. in one (1) mil film thickness. b. COVERAGE KNOWN IN GAL./SQ. YARD. MULTIPLY WITH 178.2 (CONSTANT) For example 0.18 Gal./Sq. Yard W.F.T. = 178.2 X 0.18 = 32 mils.

  20. COVERAGE RATE CONFIRMATION-SEALER FILM THICKNESS STEP 4 Calculate Dry Film Thickness (D.F.T.) SIMPLE MULTIPLY WET FILM THICKNESS (W.F.T.) WITH SOLIDS % BYVOLUME) D.F.T = W.F.T. x % solids by vol. EXAMPLE D.F.T. = 32 mils x 0.35 = 11.2 mils.

  21. DRYING & CURINGof SEALCOATINGS DRYING- EARLY STAGES CURING-FINAL FILM SET UP SEALCOATINGS CURE THROUGH: • RELEASE OF WATER , THROUGH EVAPORATION • FILM SHRINKS IN VOLUME • PARTICLES OF THE BINDER AND FILLER ARE FORCED TO COALESCE • BINDER PARTICLES SOFTEN, FUSE AND ENVELOPE CLAY/FILLER PARTICLES. • CONTINUOUS SEALER FILM IS FORMED.

  22. DRYING & CURING OF SEALCOATINGS WE WILL DISCUSS 1. CURE MECHANISM 2. FACTORS AFFECTING CURE TEMPERATURE- (SURAFCE & AMBIENT) RELATIVE HUMIDITY (% R.H.) WIND VELOCITY

  23. DRYING & CURING OF SEALCOATINGS 1. Cure Mechanism:  Sealcoatings are water-based  Water represents the largest portion of mix design (65%)  They dry/ cure by releasing water.  As water evaporates, the film shrinks in volume (to 35% remaining as dry film)  Binder (tar/asphalt) and clay/filler particles are forced in closer proximity  Binder particles touch each other and start fusing, thus enveloping clay/filler particles and bonding to the pavement  Continuous film results-Free of voids

  24. DRYING & CURING OF SEALCOATINGS CURE MECHANISM: Volume Shrinkage in Film WATER Sealer Solids only

  25. DRYING & CURING OF SEALCOATINGSCURE MECHANISM:Sealer wet film: Is multi-layered (composite) layer of many thin films Each layer dries individually from top to bottom, The release of water becomes more difficult as each layer dries Bottom layer takes longer to cure The sealer may appear fully dry on the surface but the bottom layers may still be soft.Allow sufficient drying.

  26. DRYING & CURING OF SEALCOATINGSCURE MECHANISM:

  27. 2. CURE CONDITIONS Factors Affecting Drying TEMPERATURE (ambient & surface) Min. 500 F and rising is preferred A. Lower temperatures : POOR FILM FORMATION. BINDER PARTICLES DO NOT SOFTEN PROPERLY TO FUSE AND FORM A CONTINOUS FILM It may result in: POOR PERFORMANCE. SEALER PROPERTIES ARE LOST, SELDOM RECOVER. GRAY COLOR ON INITIAL DRYING.

  28. Factors Affecting Drying (cont..)B. Higher Temperatures: Over 90o FWATER FLASHES OFF- IMMOBILIZING THE BINDER PARTICLES IN THE FILM. IT MAY RESULT INTO:TRACKING PINHOLING SAND BALLING DRYING IN THE WINDROW POOR & STREAKY APPEARANCEHumidityCapacity of the surrounding air to hold water Low Humidity: Very favorable for drying and cure. Will speed up drying.High Humidity- Slow cure. Need more drying time.WIND VELOCITY Will carry volatiles away.

  29. HumidityWater Vapor in the AirAdditional Notes Relative Humidity (R.H.) : Capacity (%) of air to hold water vapor at a particular temperature. - Low R.H.- MEANS THE AIR HAS ROOM TO ABSORB MORE WATER VAPOR. 30% MEANS 30% of the capacity used up- 70% remaining. Good for sealer drying. - High R.H.- MEANS THE AIR HAS VERY LITTLE ROOM ABSORB MORE WATER VAPOR. 80% MEANS 80% of the capacity used up- 20% remaining. Poor for sealer drying. Air is like a blotting paper.- It will keep absorbing water as long as it is not saturated. The capacity of the Air to hold water vapor will change with temperature. Higher temperature – Higher the capacity . Air will expand.

  30. CAPACITY OF AIR TO HOLD WATER VAPOR @ SATURATION VS. TEMPERATURE

  31. EVAPORATION RATE@ VARIOUS R.H. and TEMPERATURE

  32. DRYING & CURINGof SEALCOATINGS Favorable Conditions:  Moderate Temperatures  Low humidity  Moderate wind velocity Unfavorable Conditions:  Low Temperatures  High humidity  Stagnant wind GENERAL  Allow each coat to dry sufficiently, prior to applying the subsequent coating.  Take light vehicular traffic (application equipment - e.g. spray rig) scuffing and tearing.

  33. ADDITIVES 1. WHAT ARE ADDITIVES?  DEFINITION  TYPES 2. WHAT THEY DO & HOW THEY IMPROVE THE SEALER PERFORMANCE?  FAA QUALIFYING TESTS 3. WHAT THEY DO NOT DO? COMPENSATE FOR POOR PERFORMANCE, IF EXCESSIVE WATER OR SAND IS USED.

  34. ADDITIVES DEFINITIONS ADDTIVES ARE THE Materials Added to Sealcoatings to ACCOMPLISH SPECIFIC OBJECTIVES

  35. ADDITIVESOBJECTIVES IMPROVED PROPERTIES: Flexibility and elongation Toughness Water resistance Resistance to chemicals, de-icing salts, oils, fats, grease etc.. FAST DRYING: Even under not-so-ideal weather conditions. UNIFORM DRY COLOR: Under shade or shine. THICKENING: To accommodate large amounts of water. SAND OR AGGREGATE SUSPENSION: No streaking, NO SAND BALLING.

  36. ADDITIVESfor PERFORMANCE BOOSTING Have been used for the last 30-35 years. Extensively used since mid-70’s FAA specified A/B (Acrylonitrile/butadiene) rubber latex for coal tar based sealers.

  37. PERFORMANCE BOOSTINGRUBBERIZING ADDITIVES FOR SEALCOATINGS1. REDUCE TEMPERATURE SUSCEPTIBILITY; Reduce Tack and flow in summer & brittleness in winter months.2. INCREASE TOUGHNESS;Greater resistance to abrasion, scour and wear. Better retention of aggregates. 3. INCREASE FLEXIBILITY AND ADHESION;Better anchoring of aggregates.OTHER BENEFITSTHICKENING Due to pH alteration of the coating system. FAST DRYING Even under not-so-ideal weather conditions.UNIFORM DRIED COLOR

  38. RUBBERIZING ADDITIVESHOW DO THEY WORK Rubberizing additives are water emulsion of polymer molecules. Polymers (selected) have; Large chain length, heavily branched, Excellent resistance to chemicals, salts, water, weathering, etc. When mixed with the sealer: Polymer chains in sealcoating materials, 1. Form a flexible and tough network of polymer molecules, 2. Hold binder (tar, asphalt), fillers and aggregate uniformly.

  39. AS THESEALCOATING DRIES • Polymer network tightens within the film, it forces water out at a uniform rate, producing uniform dry color. • Polymer fuses onto the tar (asphalt) particles thus improving; ELXIBILITY, TOUGHNESS FUEL & CHEMICAL RESISTANCE SAND SUSPESION AND ANCHORING FAST DRYING.

  40. THE POLYMER FOR THE ADDITIVE MUST BE RESISTANT TO: WEATHERING GASOLINE, OILS, FATS SALTS PETROCHEMICALS OTHER CHEMICALS.. WEAKNESS IN THE POLYMER (ADDITIVE) WILL INTRODUCE WEAK LINKS IN THE SEALER AND MAY CAUSE PREMATURE FAILURE.

  41. Majority of thePOLYMERIC ADDITIVES:º Produce Thickening, º Speed up Drying Time, º Produce Uniform Dry Color, º Help to Suspend aggregates.But they differ in their abilities to;º Reinforce the propertieslike, Flexibility, Toughness, Temperature Susceptibility etc. º Improve resistance to Chemicals, oils, fats, grease, de-icing salts, aromatic fuels etc.

  42. ADDITIVES The Right Additive Used in Right Proportion will; Reinforce the properties, Improve the overall performance BUT WILL NOT Mix design deficiencies caused by the excessive amounts of ; Water- thinner dry films Sand/Aggregate- May not supply enough binder to satisfy the demand of the excessive amounts of aggregates used in the mix.

  43. ADDITIVES: CONCLUSIONS1. Acrylonitrile/Butadiene polymers(NBR TYPE) have the best overall properties. - They reinforce and boost the properties of asphalt and coal-tar based sealers. - better resistance to oils and other petrochemicals than Styrene/Butadiene polymers. Rest of the properties are similar.2. Polyvinyl Acetate/acrylic co-polymers (PVAs) are not recommendeddue to poor water and alkali resistance. Introduce weak spots in the film when attacked by water. Useful only as thickeners and for speeding up drying.

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