MACROSEAL

COLD MICROSURFACING,
A SOLUTION IN THE
MAINTENANCE OF ROADS
WITH HIGH LEVEL OF TRAFFIC

Author: Mr. Jesus Rincon

Technology Manager
Vietnam January2015
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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
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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.
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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 !!!
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Where is Micro-surfacing applied?

• Roads
 Roadways
 Shoulders
 Ramps
 Bridges
• Airfields
Taxiways and runways
• Streets
Roadways
Colored pavements
Bicycle paths
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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).
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SPECIFICATIONS and TESTING (II)

http://astm.org

http://www.slurry.org/downloads/A143.pdf
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MATERIALS (I)
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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.
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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
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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
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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.
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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.
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MIX DESIGN (II)

More important tests:
• Mixing (Breaking time)
• Abrasion (% minimum binder)
• Cohesion (opening to the traffic)
Other test:
• Wheel load test (% maximum binder)
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LABORATORY EQUIPMENT (I)

MIXING TEST

• Beaker
• Glass rod
• Tray

It gives information
about the cohesion,
consistency, breaking
time, curing time, etc.
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LABORATORY EQUIPMENT (II)

Cohesion tester
It gives information about type of mix an traffic opening time
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LABORATORY EQUIPMENT (III)

Wet Track Abrasion Test (WTAT)

It gives information about the minimum amount of binder in the mix
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LABORATORY EQUIPMENT (IV)

Load Wheel Tester (LWT)

It gives information about the maximum amount of binder in the mix
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MIX DESIGN (III)
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MANUFACTURING MACHINERY (I)
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COLD MICROSURFACING MACHINE DESCRIPTION

Water Aggregates Cement

tank hopper hopper
Spreader
box

Additive
Mixer
Emulsion tank
tank
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COLD MICROSURFACING MIXER

Twin axle
Triangular mixer
paddles
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Empty Working
Spreader box
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MANUFACTURING MACHINERY (II)

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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.
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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.
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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)
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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.
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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.
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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.

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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
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ADVANTAGES (IV)

According to its characteristics:

High Roughness and Texture: Safety.
High durability and energy saving:
Economy.
Good looking and appearance: Comfort.
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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.
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QUALITY CONTROL (II)
ASTM E 965, Sand patch test
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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

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COLD MICROSURFACING

FRESH MIX
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COLD MICROSURFACING

NEW AND OLD

SURFACES
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COLD MICROSURFACING

MOTORWAY
ITALY
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COLD MICROSURFACING

EXPRESS ROAD
SPAIN
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COLD MICROSURFACING

EXPRESSWAY
SPAIN
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COLD MICROSURFACING

TOLLWAY SPAIN
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COLD MICROSURFACING

EXPRESSWAY
INDIA
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COLD MICROSURFACING
EXPRESSWAY
TURKEY
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COLD MICROSURFACING

AIRPORTS
SPAIN
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COLD MICROSURFACING

HIGHWAY
CHINA
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COLD MICROSURFACING

ROADS
MOROCCO
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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)
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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€
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COST ECO – EFFICIENCY ANALISYS (III)
ENERGY
100

80

60

40
MATERIALS EMISSIONS
20

ACCIDENTS HEALTH

HAM MSF

Environmental-Footprints
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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.
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THANK YOU
VERY MUCH
FOR YOUR
ATTENTION.