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AAPA Guide To The Handling Storage Manufacture of PMB's Final Version Jan 2013 PDF
AAPA Guide To The Handling Storage Manufacture of PMB's Final Version Jan 2013 PDF
Foreword Acknowledgements
The Australian Asphalt Pavement Association (AAPA) has AAPA wishes to acknowledge the contributions of the following
prepared this guide as an aid to promoting best practice in individuals and groups:
the manufacture, storage, transport, handling and application
Technical Writer of Original Draft
of polymer modified binders. This document replaces the
John Rebbechi Roadcor Pty Ltd
previous version entitled Code of Practice: Manufacture,
Storage and Handling of Polymer Modified Binders, which was Document Review Working Group
published in June 2004. Stuart Dack BP Bitumen
Trevor Distin Boral Asphalt
A significant difference between Polymer Modified Binders Nigel Preston Shell
(PMBs) and conventional bitumen is the need for additional
care in handling to ensure that the effectiveness of the polymer
Review Groups:
or rubber crumb is not reduced by overheating, contamination,
or other degradation during storage and transport. AAPA Binder Producers’ Group
John Arvanitidis Caltex
Procedures contained in this guide are intended to provide Robert Busuttil AAPA
assurance to end users of consistent quality of hot PMB Warren Carter Downer Australia
materials produced in a controlled manufacturing environment. Stuart Dack BP Bitumen
Issues relating specifically to the production of PMBs by the Trevor Distin Boral Asphalt
addition of either polymer or rubber crumb in the field (i.e. at Gerard Gnanseelan SAMI Bitumen
the point of use) will be covered in a separate guide. Specific John Lysenko Fulton Hogan
requirements for PMB emulsions are also excluded from this Sam Maccarrone ExxonMobil
guide as these materials require different storage and Neil Morcombe Bituminous Products
handling practises. Nigel Preston Shell
Disclaimer
Although the information contained in this booklet is believed to be fundamentally correct and current at time of printing, the Australian Asphalt
Pavement Association does not accept any contractual, tortious or other form of liability for its contents or any consequences arising from its use.
REFERENCES 11
GLOSSARY 12
Reproduction of extracts from this publication may be made subject to due acknowledgement of the source.
anufacturing - all equipment used in the manufacturing process should be regularly inspected,
alibrated and maintained to ensure use, wear or failure does not cause inconsistency in the
anufacturing process.
2.3 Manufacturing process
spections and Overview
2.3.1 maintenance should be carried out and recorded in accordance with It isthe
the responsibility of the manufacturer to exclude the use
anufacturer's written procedures, and the records retained for the period defined of
in ingredients
the that have known adverse health effects and to
A general
anufacturer's qualityflow diagram for the process of PMB manufacture
procedures.
using a high shear mill is shown in Figure 1. Further notes ensure that all relevant safety precautions are followed, as set
3 Manufacturing process out in the supplier’s Material Safety Data Sheet (MSDS).
on the requirements for each element of the manufacturing
3.1 Overview
process are described in the following sections.
general flow diagram for the process of PMB manufacture using a high shear mill is shown
2.3.4in Polymer
gure 1. Further notes on the requirements for each element of the manufacturing process are
escribed in the following sections. The common generic polymer types used for the manufacture
of PMBs specified in the Austroads Framework for Polymer
Modified Binders and Multigrade Bitumens are Styrene
Bitumen
Combining Polymer Butadiene Styrene (SBS), Polybutadiene (PBD) and Ethylene
tank
Agent tank
Vinyl Acetate (EVA). These materials are generally proprietary
products manufactured to strict quality standards. Experience
Pre-blend Finished has shown that a supplier certificate of compliance provides
tank product
Mill tank adequate verification of the quality of these materials.
2.5 Temperature
While PMBs are generally manufactured for immediate delivery,
any extended storage should be documented and monitored The manufacturer should establish guidelines for the heating
to ensure product conforms to the specified characteristics. and storage of PMBs to avoid fuming or degradation of binders
in the manufacturing process, supplier storage, transport, user
2.3.8 Testing and release of product storage and application. Guidelines should include the range
of application temperatures, the maximum holding time at the
Requirements for product testing and treatment of non-
maximum application temperature, the recommended storage
conforming product are outlined in Sections 2.4, 2.6 and 3.2.
temperature and the maximum time that materials may be held
at the recommended storage temperature.
2.3.9 Loading gantry
All supply lines throughout the plant, including loading
A summary of manufacturers’ guidelines for heating and storage
equipment, should be designed and procedures established
is published in AAPA Advisory Note 7 - Guide to the Heating
so as to avoid contamination during change of product or
and Storage of Binders for Sprayed Sealing and Hot Mixed
cleaning of supply lines. The use of oils such as kerosene,
Asphalt. Manufacturers should ensure that agents and users are
diesel, or gas oil for flushing lines should be avoided. Where
provided with current guidelines if these have changed since
lines need to be flushed, it should be done with hot bitumen
publication pending updating and re-issue of AAPA Advisory
or finished product. Any oils used for flushing or cleaning of
Note 7.
supply lines should be collected and disposed of separately
and should not be added to products or components in
storage or delivery vehicles. 2.6 Non-conforming products
The manufacturer should have written procedures that specify
how non-conforming products are dealt with. Any such non-
2.4 Product testing and evaluation
conformances should be recorded and the records kept for the
The manufacturer should establish procedures to ensure that
period defined in the manufacturer’s written procedures.
conformance to the specified characteristics are maintained.
Such written procedures are normally incorporated in a
The means of control are:
quality system.
Experience and testing has shown that often a non-compliance PMBs should generally contain the following information:
in specified properties is due to degradation during transport,
reheating, cleaning transfer lines and application procedures. • Date
From time to time protocols may be established for monitoring • PMB Class
the properties of materials at the point of delivery or • Origin
application. A flow chart of sampling, recording and testing is • Sampling point
shown in Figure 3. These procedures may be used: • Manufacturing certificate number or batch number
• Customer
• As a project for the development and verification of
• Customer order number, etc.
handling protocols. Such projects may be conducted in
• Delivery details (delivery point, time and temperature)
association with a particular client (e.g. state road
• Loading information (date, time, temperature)
authority).
• Quantity/Mass of delivery
• To maintain product
• traceability.
Customer In this case field samples • Product heating information (heating start time, finish time,
are not tested, but Customer
• held order
in storage fornumber, etc.
reference testing
total heating time and temperature)
Deliveryconditions.
• contract
for compliance with details (delivery
Samplespoint,
are time and temperature)
• Loading information (date, time, temperature) • Delivery date, time and temperature.
generally retained for the duration of the contract defects
• Quantity/Mass of delivery
liability period. • Product heating information (heating start Sampling
time, finish time, total heatingshould
time be
andundertaken in
and labelling of samples
temperature)
In order to provide adequate traceability, delivery dockets for
accordance with Section 3.1.
• Delivery date, time and temperature.
Robert! 15/9/12 7:14 P
Sampling and labelling of samples should be undertaken in accordance with Section 3.1.
Deleted:
Retained
sample for
further
testing, if
required
Pass
Fail No
Re-process
Yes Heating
Sample taken Record time and en-route?
temperature
No
Material Safety Data Sheets (MSDS) are used to provide the to keep the PMB at the minimum temperature that will allow
information required to allow the safe handling of substances effective use so that the risk of thermal degradation and
used at work. MSDS must comply with the National Code of oxidation is minimised. Similarly, the time that the PMB is kept at
Practice for the Preparation of Material Safety Data Sheets, elevated temperatures prior to application should be minimised.
2nd Edition [NOHSC:2011(2003)], published by the National
Occupational Health and Safety Commission. Suppliers are AAPA Advisory Note 7 should be taken as a guide to the
responsible for provision of the MSDS which the manufacturer maximum application temperature, holding time at maximum
or importer has prepared. The MSDS addresses the safety of application temperature, storage temperature and maximum
both personnel and the physical environment. time at recommended storage temperature.
Vehicles used to transport PMBs should be emptied of the Delivery vehicles can generally transport materials for periods of
previous product to the minimum practical level to minimise up to 4 to 6 hours with only a minor loss in temperature, usually
contamination. no more than about 15°C. Where there is only a small loss in
temperature, PMBs may be transferred directly into storage
Comprehensive guidance on the procedures to follow when tanks without reheating or, where the PMB is required to be
changing grades carried within a road tanker is provided in at an application temperature, for example delivery direct to
AP-G41/08. A summary of product changeover procedures sprayed sealing operations, they may be reheated in the delivery
relevant to PMBs is provided in Table 1. Particular attention vehicle prior to transfer into the bitumen sprayer.
needs to be paid when loading hot PMB into a tanker that has
previously contained a bitumen emulsion due to the potential Where longer transport times and greater loss of temperature
for hazardous foaming and boil-over of the tank contents. are involved, materials should be periodically reheated to ensure
that temperature is maintained within the recommended limits.
Vehicles previously used for delivery of bitumen emulsion For convenience, this may be done in conjunction with regular
products should not be used for the delivery of PMB unless rest stops.
thoroughly cleaned.
The following points should be noted when reheating PMBs:
The risk of subsequent product contamination is particularly
high when vehicles have been used to transport PMBs 1. At no time should the recommended maximum temperature
incorporating rubber crumb. It is recommended that such for the material be exceeded as indicated in Advisory Note 7.
binders be transported only in dedicated tankers. 2. Bitumen road tankers or sprayers fitted with open flame
burners should never be heated while in motion.
Care should be taken to ensure that tankers that have not
3. Drivers should be in attendance and monitor the process at
been in use for some time are free from condensation.
all times while burners are in operation.
Table 1: Product changeover guidelines 4. To avoid PMB degradation, the preferred rate of heating
should be approximately 10°C per hour and not more than
Previous Load PMB 15°C per hour.
Other Refer
X to supplier for advice
Notes to Table 1:
(a) Asphalt plants and other fixed storage Representative samples may be required to be taken of a PMB
5. Tankers
Where should
a PMB is placed in abe circulated
storage duringused
tank previously heating and for attoleast
prior 20Such
its use. minutes
samplesafter
shouldheating
be taken and
duringbefore
offloading
discharge.
for hot bitumen, multigrade bitumen or a different grade of of road tankers and during transfer into bitumen sprayers prior
to the addition of cutters and adhesion agents. In the case
6. Generally,
PMB, the tank shouldtemperature checks
be emptied to the minimumshould be undertaken
practicable every four hours and reheating applied
of asphalt manufacture, a sample can be taken from the PMB
when the temperature drop is greater than 15°C.
level in order to minimise any diluting effect on the polymer
storage tank or from the ring main during circulation or use.
7. Forof PMBs
content incorporating
the delivered 15%
PMB. Where the or higher
residual contentsrubbercrumb content, circulation should be continuous
of a storage tank comprise a different grade of PMB or other
during transport and heating with the temperature being maintained within the range
Field samples should be taken at locations and frequencies as
modified binder, the manufacturer’s advice should be sought
recommended by the manufacturer and checked at agreed intervals not supplier
between exceeding 3 hours.All sampling should
and purchaser.
on any potential incompatibility with the fresh product. Table
2 provides a guide to the relative risk from contamination by be performed in accordance with the procedures described in
4.2.7 Delivery into storage tanks or bitumen sprayersAG:PT/T101.
previous tank contents
(a) Asphalt plants and other fixed storage Field samples should be clearly identified to provide traceability
(b) Road tankers, mobile storage tanks, and bitumen sprayers
from supplier to the point of sampling. Unless otherwise
Where
used a
forPMB
sprayedissealing
placed in
work a storage tank previously used for hot bitumen, multigrade bitumen or a
specified or directed, field samples are not required to be tested
different grade of PMB, the tank should be emptied to the minimum practicable level in order to
Road tankers, mobile storage tanks or bitumen sprayers immediately and should be stored in sealed containers in a
minimise any diluting effect on the polymer content of the delivered PMB. Where the residual
previously used for fluxed or cutback bitumen should be totally secure location for a minimum period of six months, or for the
contents
emptied of filling
before a storage
with PMBtank comprise
(see also a different grade
Section 4.2.5). of PMB or other modified binder, the
duration of the contract defects liability period, whichever is the
manufacturer’s advice should be sought on any potential incompatibility with the fresh product.
greater. Samples not required for further testing beyond that
Table 2 provides a guide to the relative risk from contamination by be
period may then previous
discarded.tank contents.
Notes to Table 2
Notes to Table 2 a more compatible material or using the tank, for example, with
1. Risk profile: a load or part load of hot bitumen or PMB in an application where
1. Risk profile:
Low – Residual tank contents have a low risk of performance
Low – Residual tank contents have a low risk of performance
impactproperties
the performance on the of product
the PMB arebeing added, for
not critical.
6.2.2 Cutter
A summary of the requirements for cutting back of PMBs is
provided in Austroads/AAPA Work Tip No. 27 Sprayed Sealing
– Cutting Back of Polymer Modified Binders.
Adhesion agent – A substance used for the purpose of polymer – A predominantly organic substance comprising a very
improving the adhesion between a bituminous binder and large number of chemical entities. These chemical entities may
the aggregate. The term generally refers to adhesion in the comprise identical segments (producing a homopolymer) or a
presence of water. combination of two or more different segments (producing a
copolymer).
asphalt (used rather than the US term ‘asphaltic concrete’)
– A mixture of bituminous binder and aggregate with or polymer modified binder (PMB) – A binder consisting of
without mineral filler, produced hot in a mixing plant, which is polymeric materials dispersed in bitumen with enhanced binder
delivered, spread and compacted while hot. performance for particular applications.
bitumen – A very viscous liquid or a solid, consisting essentially sprayed seal (chip seal) – A thin layer of binder sprayed onto
of hydrocarbons and their derivatives, which are soluble in a pavement surface with a layer of aggregate incorporated and
carbon disulphide. It is substantially non-volatile and softens which is impervious to water.
gradually when heated. It possesses waterproofing and
adhesive properties. It is obtained from native asphalt or by strain alleviating membrane (SAM) – A sprayed seal with the
processing the residue from the refining of naturally occurring binder containing a relatively large concentration of rubber or
crude petroleum. polymer modifier. It is used to absorb strains that occur in a road
pavement and thereby reduce reflection cracking.
bitumen emulsion – A liquid product in which a substantial
amount of bitumen (with which some oil may be mixed) is strain alleviating membrane interlayer (SAMI) – Similar to a
suspended in a finely divided condition in water by means of SAM, but provided as an interlayer before placing an asphalt
emulsifying and stabilising agents. overlay.