AUSTROADS

PAVEMENT
RESEARCH
GROUP

Transport
Research

November 1996

APRG TECHNICAL NOTE 6

SPRAYED SEALING AGGREGATE PRECOATING

Introduction
For a sprayed seal to perform, the aggregate must be
retained securely by the binder. This is strongly influenced
by:

What is precoating?
Precoating is the pretreatment of the aggregate with a thin
film of bitumen compatible material, generally a
petroleum based product, to:

a) the quantity of binder

neutralise the effect of dust

b) achieving an adequate bond between the binder and

each aggregate particle, at the time of applying the
seal, and for the life of the seal.

to aid the initial "wetting" of the aggregate by the

binder, and allow the use of a more viscous binder
(less cutter) which will set up more quickly and
improve the early retention of the aggregate

The binder rate of application needs to be carefully

designed for the conditions, the aim is to have sufficient
binder to envelop the bottom half to two thirds of each
aggregate particle. Too much binder may cause bleeding,
and too little binder may simply not be able to retain the
aggregate against the traffic stresses, leading to stripping.
There are certain conditions under which the binder may
be expected to fail to form or maintain an adequate bond
with the aggregate even with the appropriate binder
application rate. These are:
the aggregate surface chemistry
the presence of dust
the presence of water
the viscosity of the binder (may be too high for
"wetability" of the aggregate).
This can generally be improved by:
selecting the most suitable available aggregate
careful screening and/or washing to ensure that the
aggregate is clean
careful heating and proper cutting back of the binder
and
Where possible, restricting sealing to favourable
weather conditions.
Almost all aggregates contain some dust, often as a result
of loading and transporting, and being stockpiled. To
minimise the risk of stripping, it is strongly recommended
that ALL AGGREGATES BE PRECOATED.

improve the bond of the binder to the aggregate.

Types of precoat
The common precoating materials used are:
oil based - generally distillate, but a 50:50 mixture of
distillate/ kerosene, or kerosene only, may be used in
cooler weather conditions.
bitumen based ~ generally bitumen mixed with
distillate or kerosene. Bitumen content varies between
25 and 40% by volume of the mixture.
bitumen emulsion
emulsion.

generally,

diluted

cationic

Less common are water based proprietary materials

consisting of a mixture of water and adhesion agent.
Laboratory testing and field experience will assist the
practitioner to make the choice of the preferred precoating
material and adhesion agent for the conditions. Field trails
have shown that bitumen based precoats perform generally
better in severe circumstances in the long term than oil
based or water based precoats. Bitumen emulsion has the
advantage of containing little or no oil which might
reduce the early strength of the bond.

Use of adhesion agents

In Precoating
The oil based precoating materials are sometimes used
alone just to "kill' the dust. When the aggregate is damp,
or the weather conditions are unfavourable with rain

threatening or humid conditions, adhesion agent should be

added to the oil based precoating materials.
A bitumen based precoat should always contain an
adhesion agent.
In cationic bitumen emulsion, the emulsifier is similar in
action to an adhesion agent, and therefore use of an
adhesion agent is not required.
Adhesion agents may be supplied as a paste, in granular
form or as a fluid. They are chemicals designed to
improve the adhesion of the binder to the aggregate,
particularly in the presence of water. They often have a
nauseating smell, and can irritate the skin and eyes.
Therefore, the manufacturer's instructions given in the
Material Safety Data Sheets (MSDS) should be observed
at all times.
In the Binder
Adhesion agents are most effective and economical when
added to the precoating material, but they may also be
added to the binder. This is usually necessary only when
acidic (silicate/ quartz
rich) aggregates are used, or
when using a polymer modified binder. Dosing binders
with adhesion agents is particularly beneficial when
siliceous aggregates are used.
Concentration
It is important to measure accurately the quantity of
adhesion agent added in the field to the precoat or binder.
Too much adhesion agent can actually make things worse,
and result in the aggregate stripping. The typical
concentrations, (by volume) of commonly available and
used adhesion agents are:
in the precoat:

1 to 2 parts per 100 parts of

precoating material
(approx. 1 to 2%)

in the binder:

1/2 to 1 part per 100 parts

of binder (approx. 0.5 to 1%)

Precoating practice
When using oil based materials, aggregate should be
precoated in a manner to ensure a uniform film of
precoating agent is applied to all faces of the aggregate.
Aggregate may be precoated and stockpiled for a short
period just prior to use, provided precautions are taken to
protect the precoated aggregate from moisture.
When using bitumen-based or emulsion precoats, it is
preferable that the aggregate is precoated 1 to 4 weeks in
advance. This is to let the material set up and avoid pick
up by the traffic and/or softening of the binder. Precoating
of this nature may be done at the quarry prior to delivery,
or at the stockpile site. When precoated at the stockpile
site, it should be restacked neatly to allow economic and
efficient loading at the time of use. The precoated
aggregate will require protection from dust, and this may
be done with plastic sheeting or similar.
Ensure a uniform rate of precoating. The quantity of
precoating material applied should be just sufficient to
coat each aggregate particle uniformly.
A dusty, dry aggregate will require a heavier rate of
precoating than a clean, dry aggregate of the same type
and size. As a general indication only, the rate of
application of oil based precoating agent on dry aggregate
should be approximately as given in Table 1. For porous
aggregates, the rate may need to be increased by up to
2 L/m3, and for smooth, hard aggregates the rate may be
reduced by as much as 2 L/m3. Generally, bitumen based
materials and emulsion precoats require a heavier rate.

Reminder
Precoating is just one step in the chain of accepted and
well established practices, and attention to detail is
required to achieve a consistent high quality of sprayed
sealing. Precoating is not a substitute for proper
workmanship or specifying and accepting only clean
aggregates.

For further information please contact

Name
Wally Holtrop
Ted Booth
Reg Leach
Ray Gaughan
lan Cossens
Steve Hogan

Organisation
AAPA
Department of Transport SA
Main Roads WA
RTA Technology, NSW
VicRoads
Queensland Main Roads

Phone
(03) 9819 4999
(08) 260 0531
(09) 350 1444
(02) 9662 5891
(03) 9881 8915
(07) 3834 3081

Fax
(03) 9819 5278
(08) 260 0454
(09) 451 1400
(02) 9662 5123
(03) 98818900
(07) 3834 3055