ASPHALT ACADEMY

COURSE

ON

DESIGN AND CONSTRUCTION SURFACING SEALS

(A DDITIONAL N OTES }

June 2007
LIST OF CONTENTS

1 INTRODUCTION............................................................................................... 3

2 SEAL TYPE SUMMARY...................................................................................3

3 SEAL SELECTION............................................................................................4

4 SURFACING EQUIPMENT...............................................................................5

5 PLANNING AND PREPARATION....................................................................8

6 TRAFFIC CONTROL.......................................................................................18

7 REPAIR AND CLEANING PRIOR TO SEALING OPERATION.....................22

8 DESIGN AND CONSTRUCTION OF SURFACING SEALS...........................23

9 RECOMMENDED MATERIAL STANDARDS.................................................23

10 PROCESS CONTROL AND ACCEPTANCE CONTROL...............................23

11 PROBLEMS AND SOLUTIONS......................................................................23

12 CONSTRUCTION USING LABOUR-INTENSIVE METHODS.........................25

APPENDICES

APPENDIX A SEAL CONSTRUCTION CHECKLIST

APPENDIX B UPDATED PROJECT SPECIFICATIONS (NRA)
APPENDIX C DESIGN FORMS (EXAMPLES)
APPENDIX D PRE-SUPPLY MEETING AGENDA(EXAMPLE)

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1 INTRODUCTION

1.1 PURPOSE OF THIS DOCUMENT

The TRH3 (2007) is used as the base document for the Asphalt Academy Course on Seal Design and
Construction.

This document titled “ Additional Notes ”, provides information not necessarily covered in TRH3.

During presentation of each course, additional but relevant information is either discussed during the course
or requested by participants. The purpose of this document is, therefore, to provide such information to
participants and to keep record of information required for future upgrading of the TRH3 and other relevant
documents.

2 SEAL TYPE SUMMARY

 Double and multiple seals are two, or more, surface treatments. A double seal consists of an
application of bituminous binder followed by a layer of stone followed by another layer of bituminous
binder and a layer of smaller stone, often followed by a fog spray. A denser wearing and waterproofing
course is produced rather than a single surface treatment

 Cape seal consists of a bituminous binder followed by a layer of 19,0mm or 13,2 mm stone followed
by one or two applications of slurry.

 Sand seal is an application of binder covered with sand. It is used to improve the texture of an existing
surface and to waterproof it. It is also used in new construction as a single surface treatment (using
sand instead of stone) for lightly trafficked roads.

 Dust palliative is a spray of emulsion or cutback bitumen to lay dust. Polymers are sometimes added
to these products. It is also used as a binder for surface dressings on temporary deviations or lightly
trafficked roads.

 Rejuvenators are used as a temporary measure to restore some life to weathered and oxidised road
surfaces, applied in the same way as a fog spray.

 Fog seal is a light application of emulsion, usually diluted 50 percent with water. It is sprayed after the
final stone application and ensures the adhesion of the top layer of chips by coating them completely
with binder. It is also used to renew old asphalt surfaces and seal hairline cracks.

 Slurry seal and micro surfacing are mixtures of emulsion, fine aggregate, (usually crusher dust)
mineral filler and water. It is used to fill the voids between chips as in the popular Cape Seal, or to
restore old surfaces to a uniform surface texture. It also prevents water entering the pavement. It is
normally not used without a chip and spray treatment in new construction. Micro surfacing has
superior setting and adhesion properties compared against normal slurry seal.

 A choked seal can be described as an open single seal, choked with a smaller aggregate, without the
application of a binder penetration coat

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 Geotextile seals are defined as bituminous surfacings consisting of a bitumen saturated geotextile
and a conventional seal

 The Otta seal was developed by the Norwegian Roads Research Laboratory during the early 1960’s
and refers to the Otta valley where it was first used The seal consists of graded aggregates (natural
gravel or crushed rock) in combination with soft (low viscosity) binders.

3 SEAL SELECTION

3.1 Additional information regarding required skid resistance

Information published by TRL suggests minimum SFC values for specific conditions as shown below.

Notes:
Skid resistance is dependent on both micro texture and macro texture.

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4 SURFACING EQUIPMENT

4.1 GENERAL

All plant and equipment must be of adequate capacity for the project at hand, and be in good working order,
operated only by properly qualified operators.

4.2 BINDER DISTRIBUTORS

The Binder distributor is one of the most important pieces of equipment on a paving project, prime coat, and
tack coat or surface treatment operation. It is made specifically to apply liquid bitumen material uniformly and
in proper quantities to a roadway surface.

Figure 3-1 Bitumen Distributor

The person in charge must ensure that the distributor has a valid calibration certificate before spraying
commences. The sprayer and equipment shall only be driven and operated by suitably qualified people.

Accurate transverse distribution is checked on site using the “Bakkie Test”

4.3 CHIP SPREADERS

Chip spreaders are normally self-propelled and can be adjusted to various widths. Truck mounted chip
spreaders are used at times, Chip spreaders must be capable of:
o Spreading the stone chips uniformly over any width in the range of 1,5 m to a full lane width.
o Be able to control the rate of application.
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 o Stopping and starting without forming a joint line, and
o Keeping pace with the binder distributor.
o Producing a flat even layer of stone - free of ripples corrugations and unevenness

4.4 ROLLERS

4.4.1 General

Sufficient rollers of each type must be available on site to maintain the required tempo of work and be so
ballasted as not to cause crushing of the aggregate.

Pneumatic-type rollers must be self-propelled with smooth pneumatic tyres of uniform size and diameter.
The wheels must be so positioned that the tracks of the back wheels overlap the tracks of the front wheels.

4.5 BROOMS

4.5.1 Drag brooms

Drag brooms must be of the size, type and capable of distributing the stone chips evenly over the surface
without dislodging the stone chips from the binder.

4.5.2 Mechanical or Rotary brooms

These must be made available on site at all times during surfacing work. They are used for cleaning the road
prior to the seal application. A mechanical broom can be used to clean the road at any time providing that no
aggregate is dislodged from the binder.

4.6 Slurry sealing / Micro surfacing equipment

The basic equipment required for mixing and laying slurry seal consists of a special mixer mounted on a
truck and a spreader box towed behind the truck. This equipment is known as a slurry machine.

The mixer must be capable of mixing the slurry seal to a uniform blended consistency. The spreader box for
slurry must be capable of spreading a slurry seal mix in a uniform application.

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Slurry can also be mixed in a concrete mixer and spread by hand using squeegees.

Or slurry can be mixed in a small concrete (hand) mixer; this is usually limited to small surface area tasks.
More sophisticated controls are required on the machine when mixing and spreading micro surfacing.
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4.6.1 Miscellaneous equipment

Sufficient equipment for loading, handling, and hauling aggregate and binder to ensure prompt delivery must
be available. The contractor must also have available on site all the necessary auxiliary equipment, including
facilities for pre-coating of aggregate (when required), hand spraying equipment and hand tools to carry out
the work efficiently.

5 PLANNING AND PREPARATION

5.1 GENERAL

Poor performance of seals can often be traced back to inadequate planning for sealing and poor preparation
of existing surfaces prior to resealing.

Visual inspections, using TMH 9 as a guide must be carried out to determine the type and extent of failure,
the type of resealing required and the pre-seal repairs necessary.

Roads to be resealed must be repaired well in advance, including the correction of faulty drainage. One of
the most common mistakes made in repair work is that the repair is not dense enough to stop the passage of
water. In practice it is quite easy to determine the density by pouring a bucket of water over the freshly
prepared base. The water will be absorbed by the surface if it is not dense and waterproof.

Because planning and communication are so essential for successful paving operations, a pre-paving
construction conference should be held before work begins. Such a conference allows the Resident
Engineer, the Contractor’s personnel, Traffic Control personnel, Trucking personnel, and others directly
involved with the operation the opportunity to discuss topics such as the following and to plan the surfacing
operation accordingly:
 Safety
 Continuity and sequence of operations,
 Number and types of rollers needed,
 Number of trucks required,
 The chain of command for giving and receiving instructions
 Weather and temperature requirements, restrictions,
 Intermingling of aggregate from different sources,
 Construction of control strips,
 Traffic control

5.2 PLANNING FOR SEALING

Once the pre-seal repairs have been completed the actual sealing operation must be planned in detail. This
applies to new seals and resealing contracts. The work of construction starts with the planning back in the
office with scheduling, site inspection, organizing materials, and
plant. Then on site, before the work can begin, there is the site
organisation itself. Only then can the actual work process take
place.
All site activities need to be scheduled in accordance with

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contract specifications.

Aspects to be taken into consideration when planning seal operations

 Resource requirements – Availability of plant and equipment, Human resources

 Team numbers, positions, duties; Allocation of responsibilities, authorities and accountabilities, job
knowledge, skills, training
 Conditions of contract, requirements and specifications
 Obtain details of design and application rates
 Work flow, work sequences, daily workload, production, performance criteria
 Contractor’s duties and responsibilities; Subcontractor requirements
 Schedule of quantities, payment and maintenance requirements
 Reporting procedures, work activity programme, cost control and monitoring
 Plan for unforeseen circumstances – emergencies, changes in weather, equipment breakdowns,
supply problems etc.
 Health, safety and environmental considerations; Worksite safety plan, public safety
 Uninterrupted supply of approved aggregate - stockpiled at suitable locations
 Supply and storage of binders
 Traffic control

Note: Refer to Appendix D for and example of a “Pre-supply Meeting Agenda”

5.2.1 Scheduling the construction process

The scheduling of a surfacing or resurfacing requires some planning ahead. Responding to a tender,
ordering of materials, taking of samples, doing designs, and other preparations need to be thought out in
advance. It is helpful to draw a time schedule, even by hand, to guide you. While each project has its own
timing, typical schedules are shown in the figure below.

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5.2.2 GANTT time chart of construction process

5.2.3 Site inspection

Prior to construction, a site inspection should be done of each section to be surfaced. During this inspection
the following aspects must be determined:
 Exact location (start and stop) of the contract,
 Scope of work - lengths, material volumes, time, people and plant needed,
 Storage areas for aggregates and binders,
 Road preparation, including patching and crack sealing,
 Traffic accommodation - organise what is needed

.
5.3 PLANNING OF MATERIALS TESTING
The consulting engineer or road authority may have specified their own test schedule. In the absence of this,
the following materials tests are suggested.

Note: Please also refer to TRH3 (2007) Chapter 9 and the latest TG1 document.

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5.3.1 Aggregates and binders

Aspect to be Type of Control Sample Sampling

Stone seal
controlled Size Frequency
Component

Aggregate Aggregate 10% FACT or ACV 30 kg per 1 sample of each

Strengtha(Hardness) aggregate aggregate size
size

Flakiness Flakiness
Test

Size ALD

Adhesiona Riedel and Weber

Gradation Sieve
Analysis

Fines content
< 0,425mm

Dust content
< 0,075mm

Binder Specification Supplier quality ongoing

control

Water (if used in a Compatibility for Dilution test 1 litre from each source 1 per
fogspray) dilution sour
ce

Note:

a. Not usually done unless special circumstances prevail.

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5.3.2 Slurry seals & Microsurfacing

Aspect to be Sampling
Component Type of control Sample size
Controlled Frequency

Crusher dust Gradation Sieve Analysis 15 kg 1 Sample per

1000m3

Sand Gradation Sieve Analysis 15 kg 1 sample per

1000m3,
minimum of 5
samples per
source

Emulsion (Stable Specification Supplier quality Ongoing

grade anionic) control

Cement SABS SABS mark 1 per source

Water Compatibility for Dilution test

dilution

All Mixing Mix test 1 litre actual

emulsion 5kg
actual crusher dust
or sand

All Wear and Wet track abrasion

trafficking

All High traffic or Marshall test

heavy loading

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5.4 STOCKPILING
For surface seals the aggregates,
crusher dust and sands are usually
stockpiled on site. The stockpile
areas should be spread along the
road. For seals, this is usually about
5 kilometres apart (see the figure
below). The stockpile should be
placed:
 Where driver's visibility is
good, so that the stockpile
does not restrict visibility,
 Not close to intersections,
 On level, well drained ground
which is firm enough to carry
the stockpile weight. Clean the site before use.

5.4.1 Stockpile location

The stockpile area must be big enough to store the binders (static tanks and haulers) and aggregate for the
area it services:

 The binder storage tank requires approximately 25m2

 The aggregate storage area must be calculated.

Note:
Assume that 1 m3 of loose stockpiled aggregate will cover 40m2 on the road (for a single seal). Assume a pile
of 20m3 will take up an area in the stockpile of approximately 3 metres x 4 metres. Thus for enough
aggregate for a 5 kilometre single seal surfacing:
Road width = 8m
Length = 5,000m
Road surface area = 8 x 5,000 = 40,000m2
Aggregate needed = 40,000/40 = 1,000 m3
Number of 20m3 heaps = 1,000/20 = 50
Area needed = 50 x (3x4) = 600 m2

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Leave a clear area of 3 metres along one side of the stockpile so trucks can travel from one end to the other
of the stockpile, and a clear area of 10 metres at one end of the stockpiles for loading and/or precoating.

5.5 ROLE PLAYERS AND RESPONSIBILITIES

5.5.1 Seal construction team

The seal construction team would typically comprise:

1. Resident Engineer (RE)

2. Site Agent
3. Technician
4. Foreman
5. Chip spreader operator and assistants
6. Distributor operator/slurry supervisor
7. Truck drivers
8. Loader operator
9. Roller operators
10. Broom operator
11. Back chipping team
12. General workers

All of the above have different responsibilities during the surfacing operation. Although it is not possible to
discuss all the decisions to be taken during seal construction, the following should serve as a guideline.

5.5.2 PRIMING
5.5.2.1 Before priming
Decision Departmental Operation Contractor Operation
Has the base course dried out Technician RE/Site Agent
sufficiently
Has the base course been Technician/Foreman RE/Site Agent
swept to a satisfactory standard
Is the weather conducive to Technician/Foreman RE/Site Agent
priming
Is the correct prime available Technician/ Distr. Operator Site Agent /Distr. Operator
Is the prime the correct Technician/ Distr. Operator RE/Site Agent /Distr. Operator
temperature

5.5.2.2 After priming

Decision Departmental Operation Contractor Operation
Has the prime penetrated Technician/Foreman RE/Site Agent
sufficiently
Is it necessary to blind some Technician/Foreman RE/Site Agent
areas with sand
Does the base need to be Technician/Foreman RE/Site Agent
repaired in some areas
Is the application rate within Technician/Foreman RE/Site Agent
specification?

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5.5.3 CHIP AND SPRAY

5.5.3.1 Binder application

Decision Departmental Operation Contractor Operation
Cutting back the binder with Technician RE
paraffin
Is the spray certificate of the Technician RE/Site Agent
binder distributor valid
Is the weather conducive to Technician/Foreman RE/Site Agent
spraying the type of binder
Has the minimum road surface Technician RE/Site Agent
temperature been reached?
Is the binder application rate Technician RE/Site Agent
within specification?
Is the spray bar set at the Technician/Distr. Operator RE/Site Agent/Distr. Operator
correct height?
Is the nozzle spray pattern Technician/Distr. Operator RE/Site Agent/Distr. Operator
acceptable

5.5.3.2 Aggregate application

Decision Departmental Operation Contractor Operation
Is the Aggregate quality Technician RE/Site Agent
acceptable
If the aggregate has been Technician RE/Site Agent
precoated, has it dried
sufficiently so as not to stick
together
Is the aggregate spread rate Technician/Foreman RE/Site Agent
acceptable
Transverse joints is the paper Technician/Foreman RE/Site Agent
ready?
Is the surface flat and even Technician/Foreman RE/Site Agent
after application

5.5.3.3 Rolling
Decision Departmental Operation Contractor Operation
Is the correct type of roller Technician RE/Site Agent/Roller Operator
available
If a pneumatic roller is used are Technician/Foreman/ RE/Site Agent/Roller Operator
the tyre pressures correct Roller Operator
Has the surface been rolled Technician/Foreman RE/Site Agent
sufficiently
If a steel tyre roller is used, is Technician RE/Site Agent
the aggregate not crushing
excessively

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5.5.3.4 Brooming
Decision Departmental Operation Contractor Operation
Are the brooms of the Technician/Foreman/Broom RE/Site Agent
mechanical broom in a Operator
satisfactory condition
Has the binder set sufficiently to Technician/Foreman RE/Site Agent
withstand the brooming action
Has the surface been broomed Technician/Foreman RE/Site Agent
sufficiently

5.5.3.5 Opening the surface to traffic

Decision Departmental Operation Contractor Operation
Has the binder set sufficiently to Technician/Foreman RE/Site Agent
retain the aggregate?
Does the danger of loose chips Technician/Foreman RE/Site Agent
exist?

5.5.4 SLURRY

5.5.4.1 Before commencement of the contract

Decision Departmental Operation Contractor Operation
Has the surface been Technician RE/Site Agent
prepared to a satisfactory
condition?
Is the aggregate grading Technician RE/Site Agent
acceptable
Is the correct emulsion being Technician/Distributor Operator RE/Site Agent
used
Is the slurry machine free of Technician/Foreman/Slurry RE/Site Agent/Slurry
oil leaks and fully operational Supervisor Supervisor
Is the spreader box in an Technician/Slurry Supervisor RE/Site Agent/Slurry
acceptable condition Supervisor
Is the striker rubber of the Technician/Slurry Supervisor RE/Site Agent/Slurry
spreader box in an acceptable Supervisor
condition

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5.5.4.2 Laying of the Slurry
Decision Departmental Operation Contractor Operation
Is the slurry consistency Technician/Slurry Supervisor RE/Site Agent/Slurry Supervisor
acceptable
Is the cement content correct Technician/Slurry Supervisor RE/Site Agent/Slurry Supervisor
Is the slurry segregating Technician/Slurry Supervisor RE/Site Agent/Slurry Supervisor
Are the joints and edges Technician/Slurry Supervisor RE/Site Agent/Slurry Supervisor
finished off to an acceptable
standard
Is the water demand of the Technician/Slurry Supervisor RE/Site Agent/Slurry Supervisor
slurry within normal limits

5.5.4.3 Opening the surface to traffic

Decision Departmental Operation Contractor Operation
Has the slurry cured sufficiently Technician/Foreman RE/Site Agent/ Foreman
Are there any shady areas that Technician/Foreman RE/Site Agent/ Foreman
need to be closed off from
traffic

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6 TRAFFIC CONTROL

6.1 GENERAL

The provision of the necessary road signs is an important aspect of any reseal work, not only for the effective
execution of the work, but also for the safety of the traveling public.

Traffic signs for reseal work must be erected according to legislation. The person in charge of resealing units
must ensure that he is familiar with these requirements. Detailed instructions must be issued to teams
regarding the provision and placing of road signs.

The specified signs, including cones, must be available on site and in good condition before work is
commenced. On heavily trafficked roads it is of particular advantage to use portable traffic lights controlled
by two-way radio or telephone.

It is important to ensure that traffic is not allowed on a new seal until such time as an affective adhesion has
taken place between the stone and the binder, to ensure a minimum loss of aggregate. For this reason work
should be done in half-widths unless detours can be constructed.

If early opening of the road is required, after using emulsion as a spray, the surface should be covered lightly
with sand or crusher dust and distributed evenly with a hessian drag. The surface must then be back rolled
with wet wheels before opening to traffic.

Where possible arrangements must be made with the local traffic police to be on duty on site to control the
traffic. Speed of traffic over the completed seal must be controlled during the first 24 hours.

The prescribed road signs must be erected before any completed section of road is opened to travel. The
temporary road signs must be removed from the constructed section as soon as there is no longer danger of
loose stones being whipped up by traffic. Care should be taken not to leave signs up where there is no
longer danger of loose chips, since the public is then inclined to disregard all such signs.

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6.2 LAYOUT OF TRAFFIC SIGNS
The layout of traffic signs form part of the contract documentation.

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Other points to watch are:
 Do not open the new surfacing to traffic until the binder has set up sufficiently to take the traffic
 Fast traffic can damage a seal in its early life. Whenever needed, traffic control should be used to
reduce the speed of vehicles until the binder has set up.
 Turning traffic is particularly damaging on thin surfacings when they are fresh. In areas with many
intersections and no suitable deviations. The intersections may have to be surfaced with asphalt
simply so that they can opened to traffic in the shortest time.
 To prevent traffic from running on freshly sprayed surfacings, the area should be blocked off by cones
and/or barriers. This is particularly important for conventional emulsions and modified emulsions, both
of which take some time to set up.
 Men controlling the traffic (flagmen) must be stationed at each end of the work and equipped with
stop/go signs. All workmen, and especially flagmen, must wear distinctive clothing, such as safety
vests.
 Construct road back to front so that construction traffic will not ride on new surfacing. Refer to figure
below.

Explaining the back to front concept

6.3 LENGTH OF WORK SECTION

The length of work section that can be done is governed by equipment available, by the practicality of closing
long lengths of road to traffic and by the amount of traffic.
The length of the work section should be as long as possible, but it is governed by the available equipment.
Typical values are:

Conditions Length of seal work section (m)a

Urban Block length

Rural 600

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6.4 TIME TO OPENING
A thin surfacing is susceptible to damage by traffic (and the weather) early in its life, particularly in its first
four hours. Fast traffic in particular can damage a thin surfacing in its early life, and whenever needed traffic
control should be used to reduce the speed of vehicles until the binder has set up. The time to opening
varies with the weather. The time will be shorter in hot or dry or windy conditions. The time will be longer in
cool or humid conditions with nil wind. Typical times to opening are:

Surfacing type Time to opening

Prime When dry 2-7 days for normal

prime
1-2 days for quick drying prime

Fogspray When hardened: 1-4 hours

Penetration bitumen (hot) stone

After rolling and brooming
seal

Modified seal or Microsurfacing After rolling and brooming

Emulsion seal 2-4 hours after rolling and

brooming completed

Slurry When hardened: 3-12 hours

Microsurfacing When hardened: ½hr-2 hours

6.5 ROAD MARKINGS

The road markings must be established, or re-established if they have been covered over by the resurfacing.
This must be done in accordance with the road authorities standard procedures, and within the time limits
laid down.

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7 REPAIR AND CLEANING PRIOR TO SEALING OPERATION

7.1 GENERAL

The entire Chapter 6 of TRH3 (2007) forms part of the course content

7.2 ADDITIONAL INFORMATION

7.2.1 Summary of timing and scheduling of pre-treatments
Repairs and pre-treatment usually require time to settle down before any resurfacing can be done (whether
thin or thick resurfacing). Resealing with stone seals is a particular problem since the stone can easily be
punched down into any soft underlying patch; this inevitably leads to bleeding.

Time open to traffic before

Pre-treatment
resurfacinga

All continuously graded conventional asphalt work,

8 to 10 weeks
whether a scratch coat or repair of road failures

Slurry or Microsurfacing (Colmat) overlay, rut filling

8 to 12 weeks
or patching prior to a stone seal

Slurry or Microsurfacing rut filling prior to an overlay Overnight for Microsurfacing, or 2

of slurry/Microsurfacing weeks for conventional slurry

25mm thick: 3 months, or 50mm

Coldmix
thick: 6 months

Services, such as culverts, water mains, telephones, Installation well ahead of any
rehabilitation work, or trench
etc.
reinstatement 6 weeks

Notes
 Times will increase in cool or humid climates.
 If time is critical, do periodic ball penetration tests on the pretreatment and adjacent old surface.
When the differential is less than 1mm, or the corrected ball penetration is less than 2 mm, then
resurfacing can be done.

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8 DESIGN AND CONSTRUCTION OF SURFACING SEALS

8.1 DESIGN OVERVIEW

Sections 7.1 through Section 7.9 of TRH3 (2007) form part of the course content. However, the full rational
design method is excluded.

Note: Examples of design forms are provided in Appendix C

8.2 SEAL CONSTRUCTION

Section 7.11 of TRH3 (2007) forms part of the course content, describing the construction process for each
individual seal type.

9 RECOMMENDED MATERIAL STANDARDS

Although not discussed in detail as part of this course, information provided in Chapter 8 of TRH3 (2007) is
relevant to quality control aspects as discussed in Chapter 9 and will be referred to.

Note: The complete and latest COLTO updates to road related contract are either bound into this document
as Appendix B or provided as part of the course documentation in electronic format

10 PROCESS CONTROL AND ACCEPTANCE CONTROL

All aspects covered in Chapter 9 of TRH3(2007) are relevant to this course.
A general pre-construction check list is provided as Appendix A to this document.

11 PROBLEMS AND SOLUTIONS

11.1 GENERAL
Regardless of the cause, the majority of problems with seal construction relate to either:
 Fattiness/ bleeding
 Aggregate loss

11.2 BLEEDING SURFACE

Repair of a bleeding surface is dealt with under Section 6.4 and Section 6.5 of TRH3 (2007).
Note
The purpose is to create additional voids to accommodate the excess binder. Therefore, although application
of fine sand or crusher dust could temporally reduce the tackiness, it will not restore any significant macro
texture to improve skid resistance and the probability exists that bleeding and tackiness would reoccur during
hot weather and high traffic volumes.

11.3 AGGREGATE LOSS

11.3.1 GENERAL

Premature aggregate loss could occur as a result of several factors including:

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 Insufficient binder application
 Construction deficiencies
 Adverse weather conditions e.g. cold temperatures and/ or rain
 Traffic actions

The most appropriate remedial measure is dependent on the cause of distress, the degree to which
aggregate loss has already occurred, the type of seal and the risk and consequences of further damage and
windscreen losses.
Typical situations and potential remedial measures are further discussed:

11.3.2 SLIGHT OCCURRENCE OF AGGREGATE LOSS

Application of additional binder in the form of a cationic spray grade emulsion or diluted cationic spray grade
emulsion cover spray should stabilise the situation. The amount of residual additional binder required is
dependent on the macro texture (voids available), expected traffic volumes and the prevailing and expected
climatic conditions. The minimum application would typically be a 50% diluted 65% cationic spray grade
emulsion at 0,8 l/m2.

A slight application of coarse sand (Grit) after the emulsion has broken will further reduce the risk of
aggregate loss.

11.3.3 SIGNIFICANT DEGREE OF AGGREGATE LOSS

Excellent results have been obtained by converting single seals to double seals through:
 Application of binder and pre-coated coarse sand
 Application of binder and pre-coated 6.7mm aggregate or
 Application of a fine slurry to obtain a Cape Seal effect

11.3.4 HIGH DEGREE OR COMPLETE LOSS

Re-application of binder and aggregate is normally the only feasible option unless sufficient funds are
available to overlay the area with asphalt.

Due to the binder film already on the road, the risk exists that too high binder application will result in a
bleeding surface. There is no simple answer to determine the appropriate binder application rate for the
repair action and it is recommended that some trials be conducted on site for this purpose.

11.3.5 SIGNIFICANT LOSS ON JOINTS

Good results have been obtained on single seal joints by:

 Spreading modified emulsion by hand on the joint
 Placing pre-coated aggregate (slightly smaller than the existing seal e.g. using 9,5mm aggregate on a
13,2mm joint)

Design and Construction of Surfacing seals (Additional notes)

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 Rolling with pneumatic tyres
 Fogspray only the joint area

12 CONSTRUCTION USING LABOUR-INTENSIVE METHODS

Specific attention is given in this course on practical aspects as described in Section 11.4 of TRH3 (2007).

The reader is referred to SABITA Manual 12 (1994) for additional guidelines on this topic.

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 APPENDIX A

SEAL CONSTRUCTION CHECKLIST

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PRE- CONSTRUCTION CHECK
Road section Date Time
Start________ End _______
Lane Name

Item Aspect Description Checked Comments

1 Pre-treatment done, waiting periods and QA complete
 Crack sealing
 Edge break repair
 Surfacing patching
 Base patching
 Functional patching
 Rut filling
 Texture treatment
 Fog spray
2 Surface clean (no dust, mud, droppings, oil etc)
3 Vegetation at edges, fine cracks cleared
4 Spray lanes demarcated with fiber rope
 Straight 15m pinned
 Curves 2-3 m pinned
 Measured from center line
 Joint positions not under wheel tracks or
yellow line (off-set 200mm)

5 Traffic accommodation & safety

 Road signs in place
 Cones/ delineators/ barricades positions and
spacing
 Flagmen
o Approach
o At activity
o Entrances within closure
 Stop-go set-up and communications/ standby
 Safety & protective clothing
 Dust control (deviations)
 Standby traffic light system ?
 Double/ Construction traffic on new seal ?
6 Weather limitations
Applicable to binder and seal to be applied
 Past 24 hours min temp check
 Weather forecast (temp, rain & wind)
 Look up
 Air temp
 Surface temp (different positions)
 Aggregate temp
 Wind
 Base moisture/ existing surface wet?
7 Binder distributor
 Correct binder in tank
 No leaks (bitumen, oil, fuel)
 Calibration certificate
 Dipstick reference number (match with
distributor)

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  Transverse distribution (Bakkie test results
OK)
 Nozzles (type, angle)
 Spray bar height (even & according to
calibration certificate)
 Fishplates attached (position, size)
 Off-site check
o Binder temperature
o Nozzles working
o Flair shape and angle

8 Chip spreader
 No leaks
 Conveyor belt condition
 Continuous even aggregate flow
 Correct and full width application
 Dry run – check application rate

9 Rollers
 No leaks
 At least 2 pneumatics (20+ ton ballasted)
 Steel wheel if specified (5-8 tons)
 Tyre pressures
10 Trial section & regular inspection
 Traffic accommodation and safety
 Spray lane demarcation done
 Air /road temperatures confirmed OK
 Binder temperature OK
 All equipment checked for leaks/ condition
 Aggregate available
 Pre-coated quantity and quality
 Sufficient equipment
o Loader
o Trucks
o Rollers
o Brooms
 Sequence and follow distance
 Joint paper (weighed down with chips)
 Full section available to chip spreader and
rollers
 Spray overlaps and fishplate usage
 Binder application rate
 Aggregate application rate
 Back chipping, brooming to edges
 Removing of double chipping
 Rolling to edges (8-10 passes)
 Brooming
o When
o Set height
o Rolling after brooming
 Confirm competency of each operator +
o Straight lines
o Start and end on paper
 Waiting periods before 2nd applications
 Final inspection before opening to traffic
o Traffic accommodation & safety
o Stability of seal
 Confirm road marking time and procedure

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 APPENDIX B

UPDATED PROJECT SPECIFICATIONS

(Refer NRA Proforma Document on CD)

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 APPENDIX C

DESIGN FORMS
(Examples)

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 R-DES-SUR-E
Design Sheet for Surface Treatment Application
April 1994

Contract: Road: Carriageway:

Lane: Street: From km: to

Aggregate Type 6,7 mm ; 9,5 mm ; 13,2 mm ; 13,2 mm + grit ; 13,2 mm + 6,7 mm ; 19,0 mm + slurry *
Binder Type
Code
General
Traffic Counts per Lane One Way Both Ways
Heavy Vehicles per Hour / Day *
E80 per Heavy Vehicles (Estimated / Determined) *
Average E80
Traffic Factor [P]
Climatic Zone
Road Surface Condition
Texture Depth mm
Aggregate
Particulars of 1 2 3
Sample No.
Source
Type
Stockpile at km
Nominal Size mm
ALD (Measured / Calculated) * mm
Flakiness %
AIV (Dry / Wet / Glicol) %
ACV (Dry / Wet) %
10% FACT (Dry / Wet) kN
Treton Value %
Application Rate m2/m3
Binder
A = Total Cold Nett = (P . Total ALD ) Ltr/m2 = ( . ) Ltr/m2 = ( ) Ltr/m2
B = Total Reduction a Construction Traffic % C = Total %
= A (C/100) b Aggregate Hardness % = (a+b+c+d)%
=( ) Ltr/m2 c Binder Type % = ( )%
d Other (Climbing Lanes, Steep Gradients, etc.) %
D = A − B = Required Total Cold Nett = ( − ) Ltr/m2 = ( ) Ltr/m2
E = Final Spray ( Emulsion Fogspray ) (i) Diluted (60 / 65 / 70 *) % Emulsion in a ( : ) ratio
(ii) Undiluted ( ) % Emulsion
F = Cold Nett Binder of Final Spray (Fogspray) @ ( ) Ltr/m2 = ( ) Ltr/m2
G = D − F = Remainder Cold Nett Binder for First (Tack) or First and Second = ( ) Ltr/m2
Spray 1 (Tack) 2 (Penetration) 3 (Final)
Distribution of G (Remainder Cold Nett Binder) % % −
Type of Binder Anionic/Cationic *
Required Cold Nett Ltr/m2
Binder Factor −
Hot Application Ltr/m2
Increase / Decrease
Recommended Rate at Spray Temp. Ltr/m2
Slurry
Layer
Slurry Mix Proportions : per 100 kg Aggr. or per m3 Mix (Dry) *
Single / Upper * Lower
Crusher Dust kg
Crusher Dust kg
Sand (Type) kg
Cement (Type) kg
Emulsion (Type) kg (litre)
Water litre
Flow of Slurry mm
* Cross out whichever option is not applicable or delete if not applicable
Remarks Approved by:
Sheet of
Date:

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Design and Construction of Surfacing seals (Additional notes)
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 Form
Prepared by: Designed by:
SECTION: D4
Date: Date:
SEAL DESIGN TYPE OF CONSTRUCTION:
New;
Rehabilitation: 2001
Reseal: X sheet 1
of 1
Road (Street) Design Method Road (Street) Design Method
Carriageway: Principal Design method : TRH3 X Carriageway: Principal Design method : TRH3 X
Lane: Lane:
From: to Check Design method option 1: From: to Check Design method option 1:
Seal Type : Seal Type :
Binder Type : Check Design method option 2: Binder Type : Check Design method option 2:

General General
Traffic Counts per lane Lane One Way Both Ways Traffic Counts per lane Lane One Way Both Ways
Traffic Counts (Daily Average) per lane Traffic Counts (Daily Average) per lane
% Heavies % Heavies
Traffic Factor Traffic Factor
ELV / Lane / Day ELV / Lane / Day
Texture depth Texture depth
Average Ball Penetration Average Ball Penetration
Climate Zone Climate Zone

Aggregate Aggregate
Particulars of Aggregate Spray 1 Spray 2 Spray 3 Particulars of Aggregate Spray 1 Spray 2 Spray 3
Source Source
Type Type
Nominal Size Nominal Size
ALD / GKA (Measured) mm ALD / GKA (Measured) mm
Flakiness % Flakiness %
ACV (Dry / Wet) % ACV (Dry / Wet) %
10% Fact (Dry / Wet) % 10% Fact (Dry / Wet) %
Polished Stone value Polished Stone value
Sand equivalent % Sand equivalent %
Procoating fluid type Procoating fluid type
Procoating fluid rate % Procoating fluid rate %
Application Rate m2/m3 Application Rate m2/m3

Binder Binder
Design ALD = (ALD1 +ALD2) = 12.4 + 4.5 = 16.9 Application 1 Application 2 Application 3 Design ALD = (ALD1 +ALD2) = 12.4 + 4.5 = 16.9 Application 1 Application 2 Application 3
Spray l/m2 Spray l/m2
Binder Type pen Binder Type pen
Required Cold Nett l/m2 Required Cold Nett l/m2
Spraying Temperature deg Spraying Temperature deg
Recommended Rate l/m2 Recommended Rate l/m2

Slurry Slurry
Proportions per 100kg Aggregate or per m3 mix (Dry) (Texture Slurry) Layer Proportions per 100kg Aggregate or per m3 mix (Dry) Layer
Bottom Top Bottom Top
Crusher Dust type (kg) Crusher Dust type (kg)
Crusher Dust type (kg) Crusher Dust type (kg)
Sand type (kg) Sand type (kg)
Cement type (kg) Cement type (kg)
Emulsion type (kg or liter*) Emulsion type (kg or liter*)
Water (liter Water (liter
Flow of slurry (mm) Flow of slurry (mm)
*Delete if not applicable *Delete if not applicable

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 APPENDIX D

PRE-SUPPLY MEETING AGENDA

(Example)

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PRESUPPLY MEETING SCHEDULE

Presupply Meeting Date:

1 PROJECT DESCRIPTION

CONTRACT: …

CLIENT: ………………… …………………………………………………………………

CONSULTANT: ………… …………………………………………………………...

CONTRACTOR: ………… ……………………………………………...

STARTING DATE OF THE CONTRACT: ……………….……………..

END DATE OF THE CONTRACT: ………………………...……..

STARTING DATE OF THE SURFACING WORKS: ……1ST OR 2ND WEEK OF JULY 2007

QUOTATION NUMBER: ………………………………………………………………………...……..

ORDER NUMBER: ………………………………………………………………….…………….…….

2 CONTACT DETAILS

Name Cell Phone No Fax No

CONSULTANT:

- Engineer

- Residential Engineer

- Materials

CONTRACTOR:

- Contracts Manager

- Site Agent

- Assistant Site Agent

COLAS:

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- Branch Manager

- Operations Manager

- Factory Manager

- Transport Manager
PRODUCT SUPPLY, DELIVERY and STORAGE,

3.1 Product:

Anionic Emulsions: Volume Penetration Bitumen Volume

□ MS 150 ……….…. ltr □ 40/50 ……….…. ltr
□ MS 200 ……….…. ltr □ 60/70 ……….…. ltr
□ SS 60 Slurry Grade ……….…. ltr  80/100 800 000…. ltr
 SS 60 Stabilisation Grade drums.…. ltr □ 150/200 ……….…. ltr
□ SS 60 / 3 ……….…. ltr
Modified Bitumen:
Cationic Emulsions:  Colflex S (SE-2
Spec)
□ CRS 60 ……….…. ltr □ Colflex A 1 400 000. ltr
□ CRS 65 ……….…. ltr □ Gravseal ……….…. ltr
□ CRS 70 ……….…. ltr □ Colrub S ……….…. ltr
□ CMS 65 ……….…. ltr □ Loadas ……….…. ltr
□ CSS 60 Slurry Grade ……….…. ltr □ Polymod M ……….….. ltr
□ CSS 60 Stabilisation Grade ……….…. ltr ………..…. ltr
□ Rubspray 65/5 ……….…. ltr Tar:
□ Rubspray 70/5 ……….…. ltr  Precoat S
□ Novatack ……….…. ltr □ QDP 210 000.…. ltr
□ Colmat N ……….…. ltr □ ¼ Prime ……….…. ltr
□ Colmat L ……….…. ltr □ 3/12 Prime ……….…. ltr
□ Colpave ……….…. ltr ……….…. ltr
□ Colrut ……….…. ltr Special:
□ MSP 1
Cutback Bitumen: □ MSP 3 ……….…. ltr
□ CB 10 ……….…. ltr □ Colcote S ……….…. ltr
□ MC 30 ……….…. ltr □ Colseal ……….…. ltr
□ MC 300 ……….…. ltr  Colflex C ……….…. ltr
□ Dupal ……….…. ltr □ Colamine ……….…. ltr
……….…. ltr

Product 1: …80/100 SABS No…307…… No …Other……… ….

Project Specifications (min / max):

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- Softening Point: 42 - 51ºC…….………….. Penetration @ 25ºC: 80 - 100 dmm

Binder Content: ………….………………. Residue on sieving: …………………………
- Special Instruction (handling, flux, reblending): …………………………….….................
Product Temperature:
- Application: Max T°: 180ºC………………… Period: 8 hours…………………
- Storage: Max T°: 160ºC …………… Period: 7 days………….…………..
Expected Daily Consumption: ……………30 – 40 Tons………………………………………………

Date & Time for the first load on site: ……1ST OR 2ND WEEK OF JULY 2007

Product 2: …Colflex S SABS No……..……TG1 SE-2 …...…Other……… ….

Project Specifications (min / max):

- Softening Point: …57ºC min………………………Viscosity: …………………………………..
- Binder Content: ………………………….. Residue on sieving: …………………………
- Special Instruction (handling, flux, reblending): Vialit adhesion test – waivered!
(Trevor Distin to submit supporting correspondence)

Product Temperature:
- Application: Max T°: 190ºC …….…. Period: 8 hours………………
- Storage: Max T°: 180ºC Period: < 24 hours………………
150ºC > 24 hours
Expected Daily Consumption: ………24 kl………………………………………………………

Date & Time for the first load on site: 1ST OR 2ND WEEK OF JULY 2007

Product 3: ……Precoat S …………SABS No……..……TG1 No……...…Other……… ….

Ex - van der Bijl Park (Suprachem)

Project Specifications (min / max):

- Softening Point: …………………………..Viscosity: ………………………………………..
- Binder Content: ………………………….. Residue on sieving: ………………………………
- Special Instruction (handling, flux, reblending): …………………………………….................
Product Temperature:
- Application: Max T°: Ambient………………… Period: …………………………..
- Storage: Max T°: Ambient……..…………… Period: ……………………………
Expected Daily Consumption: ………2 500 ltr/day….………………………………………………..

Date & Time for the first load on site: ….….5 June 2007…………………………………………….
Colas are considering two options as detail below but will finalise during the

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course of the next two weeks.

3.2 Source of supply

Source of supply: Alternative Source of supply:

- 80/100 - BP (SAPREF)…………….. - Base Bitumen Engen. ……………..
- Cutback bitumen ………….. ………... - Cutback bitumen ………….……………...
- Emulsion - Colas - Emulsion …………………………………...
- Modified Binder - Colas - Modified Binder …………………………...
- Precoat S - ………….. - Tar …………………………………………

3.3 Ordering Procedure

- Who is going to place orders: Initially Chris Eaton and move to Transport Manager - Ricky
- To whom the order must be sent to:
- Order to be placed by  fax □ e-mail
- Default lead time for orders excluding weekends: 72 hours
- Weekly program sent on each Thursday by 13:00 pm for following week

3.4 Site Storage

Product Tank Capacity Location Power Point / Heating

Fuel

Only When It Is Necessary

1: 80/100 or Colflex S

Pump & valve lock to

20 – 30 tons On site at stockpile areas
2: Precoat S be supplied by Colas

3: ……………………

4: ……………………

Responsibilities Colas Contractor

Security At factory Consider 24 hr security on site
Loading / Offloading
Heating At factory
Spillages / Site Clean up
Safety Distributor and spraying Chipping and plant
Stock Control Daily – both agree Daily – both agree
Repairs / Maintenance

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Should binder have to stay overnight; heat control must be carefully monitored to ensure
product is not adversely affected.

4 QUALITY CONTROL

4.1 Testing Frequency

Product Test Reproducibility At Source On Site Laboratory

Limit Correlation
On
request
Penetration 2.8 % of value Ev. Batch of
1: BASE BITUMEN Softening Point 2oC Ev. Batch engineer on request

Penetration 2.8 % of value Ev. Batch Ev. Batch Yes

2: 80/100 Softening Point 2oC Ev. Batch Ev. Batch Yes

3: COLFLEX S Softening Point 2oC Ev. Batch Ev. Batch Yes

Method of furbishing plant QC test Results:

Colas will provided detailed method statement with planned quality control and testing regime (Trevor Distin).
Full spectrum of tests will only be done on product on first batch and thereafter every fifth batch.

External Test Requirements: Colas to conduct a lab correlation with SRT on full spectrum of tests to ensure
compliance to reproducibility limits. Historical correlation with SRT will also be evaluated.

4.2 Sampling Instructions

- Sample frequency and time of testing

- NUMBERING OF SAMPLES TO BE AS FOLLOWS:
- DATE:
- BATCH NO:
- SAMPLE : (i.e. A for first sample of Batch, B for second, etc)

SUPPLIER TO PROVIDE CERTIFICATE FOR BASE BITUMEN with each delivery to site.
Product Size Source Hauler Storage Sprayer

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3 Tins of 1 ltr Drawn at Colas

1: Base Bitumen each factory N/A N/A N/A
3 Tins of 1 ltr Only if 2 hrs prior to
each at needed (on spraying (on
2: COLFLEX S factory Colas N/A site) site)
Only if 2 hrs prior to
2 Tins of 1 ltr needed (on spraying (on
3: 80/100 each See note below* N/A site) site)

- Retention sample: Split samples and keep for 3 months

Colas will confirm the final source of bitumen supply and will provide historical records of Base Bitumen for
the last month (some form of track record).

*It was requested the samples ex-refinery be attained with each load. Colas will try but felt that refinery would
probably not entertain this.

Softening point has to be approved on site before spraying can commence, i.e. sample needs to be drawn 2
hours before spraying.

Concern was raised as to possible contamination of Binders from hauliers. This needs to be protected
against.

5 SPRAYING

5.1 Specifications

COLAS: Write to H&I acceptance tolerance.

Product Application Spray Min. Volume Spray Min. Road

Rate Tolerances Temperature Temp.
1: …80/100……. COLTO 4, 000 l 180ºC >25ºC
2: …Colflex S OR 4, 000 l 185ºC >25ºC
3: ………………. Proposed
4: ……………….

These are new standards in terms of spraying tolerances, which the contractor formally proposed to the
engineer (i.e. the specifications on this contract are still based on the Colto tolerances).

These new specifications include:

5.1.1 Spraying Tolerances

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Absolute value: 0.6 ltr/m2

Variable value: 5%
Whichever is the greater value.

5.1.2 Minimum Quantity

The minimum quantity on which a spraying tolerance is to be evaluated on is 4, 000 ltr.

5.2 Sprayer Tests

- Validity period for calibration certificate: 12 months - Colas to provide supporting correspondence
…………………
- Bakkie test  Yes Site □ 
Colas
Date: To be confirmed…………. Time: …………………………
Bakkie test to be done every two months.
Calculation tolerances: 5% for 80/100
7% for Colflex S
Daily Operation Testing of Spray Bar Flushing of the Spray Bar
Where On site at stockpile areas On site at stockpile areas
Time Before spraying After spraying
Into a tray which allows product to be
How sucked back Discharged into drums for re-use
Spilled material will be mixed with
gravel/material and spoilt at an acceptable Drums removed from site and disposed
Disposal spoil site. of at an approved waste fill site.

5.3 Production

Product Time Sprayer on site Expected Production Sprayer Tank Capacity

1: …80/100…….. 16 000 ltr and 8 000 ltr
25 – 40 ton/day Trailor
2: …Colflex S…..
3: ……………….
4: ……………….

5.4 Cutting Back Hot Binder

Cutter: …N/A………………. %: ………………………. Where: ………….. Time: ……………..

5.5 Special Requirements

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Colas Contractor
Protection of kerbs N/A
Traffic Control 
Hand Sprayer
 yes
□ no
At interchanges

OTHER NOTES:

The method of traffic accommodation was discussed in some depth. This is however to be looked at closer
and the correct method agreed to.

The following are to be taken into consideration:

1. Position of joint.

2. Accommodation of traffic for spraying time of distributor.

3. Lane width and use of centreline island to accommodate traffic.

4. Fish plate with low clearance to be provided to prevent binder during spraying from staining
concrete cut-off drain.

It was proposed that some x-sections be drawn in order to assist with the evaluation of the spraying options.

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PROJECT

CONTRACT NO.

DATE OF MEETING

ATTENDANCE REGISTER

NAME ORGANISATION TELEPHONE FAX e-MAIL

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