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GUIDE TO THE MANUFACTURE, STORAGE AND

HANDLING OF POLYMER MODIFIED BINDERS

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

Austroads Asphalt Research Working Group (ARWG)

Austroads Bituminous Surfacings Working Group (BSWG)

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.

GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS


Contents
1. INTRODUCTION 1 4 TRANSPORT, STORAGE AND APPLICATION 6
OF PMBs
2. MANUFACTURE 1 4.1 General handling and safety requirements 6
2.1 General 1 4.2 Special requirements for PMBs 6
2.2 Equipment 1 4.2.1 Temperature 6
2.3 Manufacturing process 2 4.2.2 Moisture 6
2.3.1 Overview 2 4.2.3 Cleaning materials 6
2.3.2 Bitumen supply and storage 2 4.2.4 Segregation 6
2.3.3 Combining agent 2 4.2.5 Loading of delivery vehicles 7
2.3.4 Polymer 2 4.2.6 Reheating during transport 7
2.3.5 Pre-blending 2 4.2.7 Delivery into storage tanks or 8
2.3.6 Mixing 2 bitumen sprayers
2.3.7 Storage of finished product 3 4.2.8 Field sampling 8
2.3.8 Testing and release of product 3
2.3.9 Loading gantry 3 5 ASPHALT WORK 9
2.4 Product testing and evaluation 3 5.1 General 9
2.5 Temperature 3 5.2 Production of asphalt mixes 9
2.6 Non-conforming products 3 5.3 Placement and Compaction 9

3 SAMPLING AND TESTING 4 6 SPRAYED SEALING WORK 9


3.1 Sampling 4 6.1 General 9
3.2 Laboratory Testing 4 6.2 Field procedures 9
3.3 Tracing Properties of Delivered Materials 5 6.2.1 General handling requirements for PMBs 9
3.4 Material Safety Data Sheet (MSDS) 6 6.2.2 Cutter 10
6.2.3 Adhesion Agent 10
6.2.4 Aggregate Precoating 10

REFERENCES 11

GLOSSARY 12

Australian Asphalt Pavement Association Limited (AAPA)


AAPA is a non-profit organisation formed to promote the economic use of asphalt based on sound technical grounds. The Association’s Mission
Statement for Research and Development is to ensure the attainment of the optimum level of quality and long-term performance in flexible
pavement design, construction and maintenance. The AAPA Technology Committee manages the AAPA R&D Program for Asphalt Research
and Technology and works in close cooperation with the Austroads Pavement Reference Group. The research programs are coordinated and
complementary.

Reproduction of extracts from this publication may be made subject to due acknowledgement of the source.

GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS


1. INTRODUCTION
This guide to best practice has been prepared by the Austroads Modified Binder Test Methods
manufacturers and users of Polymer Modified Binders (PMBs) ( http://www.austroads.com.au/pavements )
to: AAPA Advisory Note 7: Guide to the Heating and Storage of
Binders for Sprayed Sealing and Hot Mixed Asphalt
• Provide guidelines for the manufacture and handling of
Australian Dangerous Goods Code, 7th Edition (October 2011).
hot PMBs.
• Provide assurance to end users of the consistent
Other relevant publications are referenced at the end of this
manufacturing quality of delivered products.
document, including Austroads guides, Technical Reports and
• Reduce the potential for degradation and contamination
Pavement Work Tips.
due to inappropriate handling or heating during the
delivery, storage and application processes.

PMBs generally consist of a blend of paving grade bitumen


and polymer or rubber crumbs. In some cases, combining
2. MANUFACTURE
agents and other additives are added to the base bitumen to
2.1 General
assist in blending and achievement of particular performance
characteristics. The normal safety, quality and environmental The manufacturer should establish, document and maintain a
considerations involved in the manufacture, storage and quality system to ensure that the products supplied conform to
handling of a PMB includes: the stated specifications. The quality system should consist of
procedures, regular inspections and tests and/or assessments
• Accurate blending of materials and control of manufacture and the use of the results to control the quality of the finished
to ensure that the product conforms to the required product. A quality system conforming to the requirements of ISO
specification. 9001 and made specific to the requirements of the Austroads
• Monitoring and control of temperature at all phases Specification Framework for Polymer Modified Binders and
of manufacture, storage, transport and field use to avoid Multigrade Bitumens and the AAPA Guide to the safe use of SBS,
premature deterioration of polymers or rubber crumbs at is considered to satisfy the above requirements.
high temperatures.
• Maintenance of the homogeneity of some mixtures that The results of inspections, tests or assessments requiring
may segregate. action should be recorded, as should any action taken. The
• Avoidance of contamination with other products that may action to be taken when control values or criteria are not met
alter performance characteristics of the product. should be recorded and retained for the period specified in the
manufacturer’s quality procedures.
A number of different organisations may be involved in the
manufacture, sampling and testing, transport and application 2.2 Equipment
of PMBs. Control throughout the process needs to be
Testing - all laboratory weighing, measuring and testing
coordinated and responsibility accepted by the various
equipment should be calibrated and regularly inspected
organisations.
according to documented procedures, frequencies and criteria.

This guide is intended to be complementary to the following


Manufacturing - all equipment used in the manufacturing process
publications:
should be regularly inspected, calibrated and maintained to
AAPA HS&E Guide No. 5: Guide to the safe use of SBS ensure use, wear or failure does not cause inconsistency in the
Austroads Bituminous Materials Safety Guide, AP-G41/08 manufacturing process.

Austroads Specification Framework for Polymer Modified


Inspections and maintenance should be carried out and recorded
Binders and Multigrade Bitumens, AG:PT/T190
in accordance with the manufacturer’s written procedures, and
Austroads Guide to the Selection and Use of Polymer the records retained for the period defined in the manufacturer’s
Modified Binders and Multigrade Bitumens, AP-T42/06 quality procedures.

GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS 1


esting - all laboratory weighing, measuring and testing equipment should be calibrated and
gularly inspected according to documented procedures, frequencies and criteria.

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.

The characteristics of rubber crumbs used in the modification of


Loading Gantry bitumen are specified in Table 5.5 of the Austroads Specification
Framework for Polymer Modified Binders and Multigrade
Bitumens, AG:PT/T190. Incoming rubber crumb should be
Figure 1: Manufacturing process
Figure 1: Manufacturing process
3.2 Bitumen supply and storage tested for compliance against these requirements. Every effort
he consistency and quality of the base bitumen used for PMB manufacture should be monitored, should be made to ensure that the rubber crumbs are free of
r example, through
2.3.2 the use
Bitumen of supplier's
supply certificates of compliance, to ensure appropriateness
and storage for
moisture and foreign materials, such as steel and fibre. Rubber
MB manufacture. Similarly, bitumen in storage should be monitored to ensure no adverse changes
crumbs should be stored in a manner that prevents exposure to
ccur thatThe
mayconsistency andPMB
adversely impact quality of the
quality. base bitumen
Systems usedprocedures
should identify for for assessing the
fluence PMB
of changes in source should
manufacture of bitumen
be materials
monitored,on the
forrequired proportions
example, rain and moisture.
throughof other component
aterials and/or properties of the manufactured PMB.
the use of supplier’s certificates of compliance, to ensure
appropriateness for PMB manufacture. Similarly, bitumen in 2.3.5 Pre-blending
olymer Modified Binders Guide 2 September 2012
Where raw materials are required to be pre-blended, procedures
storage should be monitored to ensure no adverse changes
occur that may adversely impact PMB quality. Systems should should be established and documented for proportioning,
identify procedures for assessing the influence of changes mixing and storing the blended material.
in source of bitumen materials on the required proportions
of other component materials and/or properties of the 2.3.6 Mixing
manufactured PMB. Component materials should be thoroughly mixed to ensure
production of a homogeneous PMB. The design of mixing
2.3.3 Combining agent equipment varies considerably depending on the type of PMB
being manufactured and can vary from high shear mills used
Combining agents are sometimes added to PMBs to improve
to blend SBS pellets to low shear agitation for blending rubber
their performance properties and shelf life and should comply
crumbs. Critical elements that are common to all processes
with the requirements of the AAPA Guide to the safe use of
include procedures for proportioning of materials, temperature
SBS. Acceptance criteria and storage conditions for combining
control, mixing time and conditions, and maintenance and
agents should be documented.
cleanliness of equipment.

Most PMBs are sufficiently stable at normal processing and


application temperatures. However, the inclusion of combining
agents and other additives, coupled with higher temperatures
than normally used with conventional bitumen, can produce a
noticeable increase in fuming.

GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS 2


2.3.7 Storage of finished product b) Routine control of product quality should be on a basis of
Tanks for the storage of finished product should be designed checks, of a type and frequency to be defined and
to minimise deterioration in storage, with strict control of documented, to ensure that properties do not change
temperature, minimal surface area to reduce oxidation, and significantly from those specified.
provision for mixing or circulation to ensure that the product
remains homogenous in storage. The heating system should NOTES:
be designed such that the PMB is not exposed to high 1. Where testing is required on each batch, a batch is
contact temperatures around the heating elements or flues for considered to be the quantity of binder produced and
prolonged periods. Prolonged exposure of PMBs to heating stored in one tank once the production run into that tank
elements may result in deterioration and carbonisation of the has been completed. The batch can be considered to
binder. It is essential to provide good circulation of the PMB remain the same as long as no new production has been
around heating elements or flues, either through the use of added.
mechanical stirrers and/or by circulating the tank contents
2. The manufacturer should establish manufacturing targets
with a pump. A tank heating system commonly used for PMB
for all test properties. Manufacturing targets may be
storage uses heat transfer oil and automated temperature
different to specification limits.
controls to limit overheating.

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.

a) By determining the appropriate PMB characteristics


using the tests and test frequencies specified in the
Austroads Specification Framework for Polymer Modified
Binders and Multigrade Bitumens (AG:PT/T190);

GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS 3


3. SAMPLING AND TESTING
3.1 General Sampling should be accompanied by a visual check for
uniformity, texture or unusual odour. Any observation of unusual
A means should be provided to safely take a representative
sample characteristics should be recorded on the sample
sample from any point in the supply chain. All materials
container.
should be sampled in accordance with Austroads test method
AG:PT/T101, Method of sampling polymer modified binders,
The following information should be provided with the sample,
polymers and crumb rubber, which provides for:
either on the label (see example Figure 2) or an accompanying
form (see AG:PT/101 for full requirements):
• Sampling of raw materials (polymer and rubber crumb)
• Sampling of PMBs: • Designation or classification of the material being sampled
- From bulk storage • Identification mark
- During loading • Name of supplier/manufacturer
- From rail and road tankers • Date, time and location of sampling
- From sprayers. • Type, batch number and identifying number of container,
vehicle or storage tank from which the sample was taken
It is important to ensure that samples collected are truly • Quantity of bulk material being sampled
representative of the material being sampled. • Temperature of material being sampled
Therefore it is essential that PMBs are • Name of sampler
thoroughly circulated and polymers and rubber • Any other comments.
crumbs are thoroughly mixed prior to sampling
to ensure they are homogeneous and that PMB SAMPLE
PMB SAMPLE
samples are representative. Product nameProduct
& gradename
_______________________ OLEXOBIT AB6
& grade _______________________ (A10E) AB6 (A10E)
OLEXOBIT
Manufacturer Manufacturer
______________________________ BP Australia BP Australia
______________________________
All bulk storage tanks should be fitted with Date, time & location of sampling _______________ 22/4/2004 10:35
Date, time & location of sampling _______________ BP Altona
22/4/2004 10:35 BP Altona
Sample identification________________________ 1234
a sampling valve to facilitate sampling in Sample identification________________________ 1234
Batch / delivery docket
Batch number
/ delivery ________________
docket A04P0443
number ________________ A04P0443
accordance with AG:PT/T101. Sampling valves
Tank / vehicleTank
number _______________________
/ vehicle ALB201
number _______________________ ALB201
should be situated in a convenient and safe Quantity & temperature
Quantity &oftemperature
material being sampledbeing
of material _ sampled
24,000 L _at 186°C
24,000 L at 186°C
location for sampling and a permanent platform Name of sampler ___________________________ Fred Jones
Name of sampler ___________________________ Fred Jones
attached to support the sample container Comments_________________________________ Sample for release
Comments_________________________________ testing
Sample for release testing
during filling. After filling, the sample container
should be placed in a safe location and allowed
Figure 2: Example
Figureof2:sample label
Example of sample label
to cool. Figure 2: Example of sample label
All samples All
should be handled
samples should in
beaccordance
handled in with Austroads
accordance withtest method test
Austroads AG:PT/T102, Protocol
method AG:PT/T102,
for Handlingfor
Modified Binders
Handling in Preparation
Modified for Laboratory
Binders in Preparation forTesting.
Laboratory Testing.
The sample size should be sufficient to allow all required All samples should be handled in accordance with Austroads
3.2 Laboratory
3.2 Testing
Laboratory Testing
testing and generally will be at least one litre. Reheating of test method AG:PT/T102, Protocol for Handling Modified
Laboratory testing should
Laboratory be undertaken
testing inundertaken
should befora NATA accredited
in a NATA facility and in
accredited accordance
facility and inwith the
accordance
samples should be avoided. Binders
relevant Austroads test in Preparation
methods. Laboratory Testing.
relevant Austroads test methods.
The types of The
teststypes
and minimum frequency
of tests and minimum offrequency
testing should be in should
of testing accordance
be inwith the requirements
accordance with the req
All sampling should be undertaken by properly trained 3.2 Austroads
Laboratory Testing
as set out in as
the set out in theSpecification Framework for
Austroads Specification Polymer for
Framework Modified
PolymerBinders and Binders
Modified Multigrade
and M
Bitumens (AG:PT/T190) or as agreed between
Bitumens (AG:PT/T190) the supplier
or as agreed between and the purchaser.
the supplier and the purchaser.
and qualified personnel. The unit of competency on Safely Laboratory testing should be undertaken in a NATA accredited
Handling Bituminous Materials, which forms part of a facility and in accordance with the relevant Austroads test
3.3 Tracing
3.3 Properties
Tracingof Deliveredof
Properties Materials
Delivered Materials
Certificate II in Bituminous Surfacing, should be used as methods.
Experience and testing has
Experience and shown
testing that
has often
showna that
non-compliance in specified in
often a non-compliance properties
specifiedisproperties
due to
a guide to national competency training and assessment degradation degradation
during transport,
duringreheating,
transport,cleaning transfer
reheating, linestransfer
cleaning and application
lines and procedures.
application From
procedu
standards. time to time time
protocols
to may
time be established
protocols may befor monitoring
established forthe propertiestheofproperties
monitoring materials of
at the point of
materials at th
The types
delivery or application. of tests and minimum frequency of testing should be
delivery or A flow chartAofflow
application. sampling, recording
chart of andrecording
sampling, testing isand
shown in Figure
testing is shown3. These
in Figure
procedures may be used:may bewith
in accordance
procedures used:the requirements as set out in the Austroads
• As a project for athe
•Specification
As development
project Frameworkand verification
and of
for Polymer
for the development handling
Modified
verification protocols.
Binders
of handling Such projectsSuch
and
protocols. mayprojec
be
conducted inconducted
associationinwith a particular
association withclient (e.g. state
a particular road
client authority).
(e.g. state road authority).
Multigrade Bitumens (AG:PT/T190) or as agreed between the
• To maintain
• Toproduct traceability.
maintain product In this case field
traceability. samples
In this are not
case field tested,
samples arebut
notheld in storage
tested, forin s
but held
referencesupplier
testing forand
reference the for
compliance
testing purchaser.
with contractwith
compliance conditions.
contractSamples are Samples
conditions. generallyare
retained for the
generally retain
duration of the contract
duration of defects liability
the contract period.
defects liability period.
In order to provide
In orderadequate traceability,
to provide delivery dockets
adequate traceability, for PMBs
delivery docketsshould generally
for PMBs contain
should the co
generally
following information:
following information:
• Date • Date
• PMB Class
• PMB Class
• Origin • Origin
• Sampling
• point
Sampling point
GUIDE TO THE MANUFACTURE, STORAGE AND
• HANDLING
Manufacturing
• OF POLYMER
certificate
Manufacturing number MODIFIED
or batch
certificate or batch BINDERS
number
number number 4
Polymer Modified Binders Guide 6 September 2012
3.3 Tracing Properties of Delivered Materials

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

Release Binder Yes


Binder
tests carted
production
performed direct to
site

Fail No
Re-process

Sample taken Intermediate storage

Yes Heating
Sample taken Record time and en-route?
temperature

No

Sample taken Record time & temperature Delivery to site

Figure 3: Sample traceability flow chart

GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS 5


Polymer Modified Binders Guide 7 September 2012
3.4 Material Safety Data Sheet (MSDS)

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.

PMBs should never be heated to a temperature greater than the


recommended maximum application temperature. Generally,
4. TRANSPORT, STORAGE AND only the quantity required for immediate use should be heated

APPLICATION OF PMBs to the application temperature and reheating avoided, where


practicable.

4.1 General handling and safety requirements


4.2.2 Moisture
PMBs are transported and applied hot. Safety and handling The presence of even small quantities of water can cause
procedures that are applicable to hot bituminous materials foaming and “boil-over” of hot PMB. Care should be taken
also apply to PMBs and are described in detail in the Austroads to ensure that road tankers, storage tanks or bitumen sprayers
Bituminous Materials Safety Guide, AP-G41/08. are free from water arising from the presence of condensation
or residual bitumen emulsion. A visual check for condensation
4.2 Special requirements for PMBs should always be made where tanks have been out of service for
In addition to the general handling and safety procedures some time.
applicable to all bituminous materials, attention should be paid
to those issues which have the potential to cause a reduction in 4.2.3 Cleaning materials
the quality and effectiveness of PMBs. These include: It is preferable to use diesel or high-flash kerosene to flush lines.
The amount of cleaning material should be kept to a minimum
• Effect of excessive temperatures, extended periods of and drained from tanks and delivery lines for separate disposal
storage at elevated temperatures, and/or multiple in accordance with local requirements. Cleaning materials
reheating cycles. should not be flushed into binder storage tanks or delivery
vehicles.
• Potential for contamination during change of product in
transportation vehicles and storage tanks.
Kerosene or other types of approved cutter oil used for cleaning
• Potential for contamination with materials used for
delivery lines may be drawn into bitumen sprayers where the
cleaning and flushing supply lines.
PMB is being prepared for spraying. An allowance for the
• Potential for some PMB mixtures to segregate in storage. quantity of cutter oil used for cleaning should be made in
• Method of reheating, e.g. need to recirculate product determining the total quantity of cutter oil to be added.
while reheating.
4.2.4 Segregation
As a further confirmation that PMBs have not suffered undue Some PMB types, particularly those modified by rubber crumb
deterioration during transport, samples may be required of the or high levels of SBS polymer, are susceptible to segregation
product at the point of delivery or immediately prior to use in during long distance transport and long term storage.
asphalt mixtures or sprayed sealing work (see Section 3.3). Manufacturers should advise users of susceptible materials and
provide guidelines for minimising segregation and/or remixing.
4.2.1 Temperature Users should adhere to manufacturer’s guidelines where
PMBs should not be heated to, stored or held at temperatures applicable. The use of stirrers in storage tanks and belly augers
or for periods greater than that recommended by the in sprayers will help ensure homogeneity can be maintained for
manufacturer. During handling, every effort should be made PMBs that are susceptible to segregation.

GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS 6


4.2.5 Loading of delivery vehicles 4.2.6 Reheating during transport

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.

Bitumen OK 5. Tankers should be circulated during heating and for at least


Cutback bitumen primers & Drain 20 minutes after heating and before discharge.
precoats
6. Generally, temperature checks should be undertaken every
Bitumen emulsion Drain & flush
four hours and reheating applied when the temperature

Fuel oil Drain & flush drop is greater than 15°C.

7. For PMBs incorporating 15% or higher rubber crumb


Suspected presence of Drain & flush
content, circulation should be continuous during transport
moisture
and heating with the temperature being maintained within
PMB OK
the range recommended by the manufacturer and checked
at intervals not exceeding 3 hours.
Crumb rubber bitumen 4 Standard bitumen loads*

Other Refer
X to supplier for advice

Notes to Table 1:

1: OK: OK to load. In all cases the previous product


OK to load.should be fully
In all cases thedrained.
previous product should be fully drained.
Drain & Drain
Flush:
vehicle of productofand
Drain vehicle product
flushand flush
with with
kerosene wash and fully drain and
kerosene
dry out, or boil washuncontaminated
out with and fully drain and dry out, grade
standard or bitumen as per your
boil out
company’s work with uncontaminated standard grade
instruction.
bitumen as per your company’s work
men loads: Should take minimum 4 loads of C170, C320 or C600 prior to loading.
instruction.
4 standard
Refer Shouldfor
to supplier take minimum
technical 4 loads of C170, C320
advice.
bitumen loads: or C600 prior to loading.
ing during transport
cles can generally transport materials for periods of up to 4 to 6 hours with only a
temperature, usually no more than about 15°C. Where there is only a small loss in
MBs may be transferred directly into storage tanks without reheating or, where the
ed to be at an application
GUIDE TO THEtemperature,
MANUFACTURE,for example delivery direct
STORAGE ANDto sprayed sealing
HANDLING OF POLYMER MODIFIED BINDERS 7
y may be reheated in the delivery vehicle prior to transfer into the bitumen sprayer.
4.2.7 Delivery into storage tanks or bitumen sprayers 4.2.8 Field sampling

(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.

Table 2: Relative risk from contamination by previous tank contents

Previous tank Product being delivered


contents
Cutback Bitumen Bitumen Low modification High Crumb rubber
bitumen emulsion PMB modification bitumen
PMB
Cutback bitumen Not applicable See note 2 Medium Very high Very high High
Bitumen emulsion See note 3 Note 6 See note 3 See note 3 See note 3 See note 3
Bitumen Medium See note 2 Not applicable Medium High Medium
Low modification PMB Medium See note 2 Low Not applicable Medium Medium
High modification PMB Medium See note 2 Low Medium Not applicable Medium
Crumb rubber bitumen See Note 4 See note 2 See Note 4 See Note 4 See Note 4 Not applicable

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.

impact on theexample topping


product being added,up
for of modified
example toppingbinder
up of with hot bitumen may enhance rather than detract
2. Storage of bitumen emulsion in tanks previously used forfrom
hot
bitumen products usually requires the tank to be completely
normal
modified binder usebitumen
with hot of bitumen.
may enhance rather than
emptied and cleaned before adding bitumen emulsion.
detract from normal use of bitumen.
Medium
Medium – While
– While residual residual tank
tank contents maycontents may not have a3. major
not have a major impact materials
Hot bituminous on performance
should not beof added
added product,
to tanks previously
tank levels
impact on performance should
of added generally
product, be should
tank levels reduced to minimum usedlevels before
for bitumen adding
emulsion new
unless materials
all traces of moisture have been
removed.
generally be reduced to minimum levels before adding new
High – Reduction of tank contents to minimum level is
materials. 4. essential.
Care shouldLow levels
be taken of contamination
when adding materials to tanksmay be
that have
tolerated but generally not more than
High – Reduction of tank contents to minimum level is essential. 10% of diluting
beenproduct.
used for storage of crumb rubber modified binder. Usually
a series of loads of hot bitumen or hot cutback bitumen are
Very
Low high
levels – Contamination
of contamination couldbut
may be tolerated have a serious
generally not impact on performance.
required Preferably,
before use for theapplication.
any other critical tank should be
more than 10% of diluting product.
completely emptied prior to adding new materials. Where complete
5. Multigrade to be treatedemptying is not for
the same as bitumen practicable,
product
Very high – Contamination could have a serious impact on
risk should be reduced by flushing
performance. Preferably, the tank should be completely emptied the tank with achangeover
more compatible
purposes material or using the tank,
for example, with a load or part load of hot bitumen or PMB in an application where
prior to adding new materials. Where complete emptying is not 6. Refer to AP-G41/08 Austroads Bituminous Materials Safety the
Guide
practicable, risk should be reduced by flushing the tank with for specific requirements
performance properties of the PMB are not critical.
2. Storage of bitumen emulsion in tanks previously used for hot bitumen products usually requires the tank
to be completely emptied and cleaned before adding bitumen emulsion.
GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS 8
3. Hot bituminous materials should not be added to tanks previously used for bitumen emulsion unless all
traces of moisture have been removed.
5. ASPHALT WORK
5.1 General Some PMBs emit fumes at high temperatures. Such fumes can
PMBs for asphalt work should be transported, transferred and lead to eye and throat irritation, or even to headaches and
stored in accordance with Section 4. nausea. Therefore, it is important to follow the manufacturer’s
recommendations with regard to handling conditions and the use
5.2 Production of asphalt mixes of appropriate personal protective clothing and equipment. The
AAPA Guide to the safe use of SBS, AAPA Advisory Notes 7 and
Asphalt produced from pre-blended PMB should be mixed
14, Austroads/AAPA Work Tip 13 and AAPA training programs
and handled in accordance with the recommendations of the
address such issues and provide a guide to best practice. Further
PMB manufacturer/supplier. Such recommendations may refer
guidelines for the use of PMBs in asphalt are provided in the
to asphalt mixing temperatures, mixing times and specific
Austroads Guide to the Selection and Use of Polymer Modified
measures to minimise heat loss during transit.
Binders and Multigrade Bitumen AP-T42-06

Asphalt incorporating a PMB can also be produced by the


addition of rubber crumb and other selected granular polymers
into the asphalt mixing process, but only in a batch type
6. SPRAYED SEALING WORK
pugmill or double drum mixer. Addition of some polymers, 6.1 General
such as EVA and rubber crumb, direct to the pugmill should
PMBs for sprayed seal work should be stored, transported and
also be in accordance with the recommendations of the
transferred in accordance with Section 4. Any increase in binder
polymer supplier. Increased wet mixing times may be required
cohesion (internal strength) as a result of polymer modification
to achieve a satisfactory distribution of the polymer through
usually is accompanied by a decrease in binder wetting ability
the asphalt mixture.
and therefore its ability to adhere to, or retain aggregate. These
characteristics require modification to field procedures as
The modification of bitumen generally results in an increase
described in the following section.
in the binder viscosity and therefore the asphalt mixing
temperature may need to be increased to ensure adequate
6.2 Field procedures
coating of the aggregate and workability of the asphalt.
6.2.1 General handling requirements for PMBs
Inappropriately high asphalt mixing temperatures may lead to PMBs are generally handled and applied similarly to Class
segregation, binder degradation and binder drainage, which in 170 bitumen using conventional sprayed sealing equipment.
turn can adversely affect performance of the asphalt. Excessive However, PMBs require increased attention to detail and special
temperatures may also cause unwanted fuming. Refer to consideration of the field construction practices to ensure
AAPA Advisory Note 7 for details of the appropriate asphalt satisfactory adhesion between the binder and the aggregate.
production and paving temperatures for the various PMBs.
PMBs are more viscous than Class 170 bitumen and may
5.3 Placement and Compaction form a “skin” in cooler weather conditions. For details on
Additional care is needed to achieve specified requirements for the appropriate minimum road surface and binder spray
riding quality, compaction and surface finish when placing and temperatures for the various PMBs, refer to either the PMB
compacting asphalt incorporating PMB. To achieve adequate supplier or the AAPA Advisory Note 7.
compaction, the mix temperature may need to be increased by
up to 15°C over conventional bitumen, depending on the type In addition to normal good practice, the following procedures
and degree of modification. Loss of workability on cooling will should be followed:
necessitate greater attention to:
• weather conditions; • The time taken to spread aggregate onto a PMB must be
• layer thickness and mix type; kept as short as practically possible and the aggregate
• timing of operations; spreading and rolling operations should be kept as close as
• rolling patterns and techniques; possible behind the sprayer. This is done to ensure
• scheduling of deliveries (avoid starts and stops); aggregate adhesion has the best chance of developing
• joints (minimise); while the PMB is still hot and may necessitate shorter than
• handwork (to be avoided); and usual sprayer runs or additional rolling capacity.
• prevention of pick-up on rubber-tyred rollers (pre-heat).

GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS 9


• If using a particular class of PMB for the first time, it is Additional advice on cutting back of PMBs and other sprayed
advisable to check with the manufacturer about any special sealing construction practices are provided in the Austroads
handling or application requirements. Guide to the Selection and Use of Polymer Modified Binders and
• For a SAM or SAMI application, the pavement and air Multigrade Bitumens or may be obtained from manufacturers or
temperatures need to be above 20°C and rising. Higher suppliers.
temperatures are required if wind chill is expected to cool
the binder quickly after spraying. Wind chill will cause the Take extreme care when blending cutter oil with PMB. AP-G41/08
binder to “skin” more quickly and this will delay, or should be consulted for further information.
prevent, wetting and development of adhesion.
The exception to this is S35E produced with PBD, which 6.2.3 Adhesion Agent
may be used at the lower pavement and air temperatures In general, hot PMBs are more viscous and cohesive than
normally accepted for Class 170 work (approximately conventional bitumen and consequently less able initially to
15°C), but only where recommended by the manufacturer. wet and adhere to aggregate particles. If there are problems
• The presence of moisture in any form should be avoided. developing adequate adhesion between the PMB and the
Avoid spraying PMBs in changeable weather conditions. aggregate, then it is recommended to promote bonding by
Spraying should only be applied to a dry pavement surface adding extra adhesion agent. A general rule of thumb in this
and aggregates should be precoated and dry (at most case is to double the concentration of adhesion agent compared
damp). This may require the aggregate stockpile to be to conventional bitumen, i.e. add about 1% of adhesion
covered with waterproof material. agent instead of 0.5%. The adhesion agent selected should
• Warm and dry weather conditions before and after be compatible with the type of polymer in the binder and the
application of the PMB seal are essential. Wet weather aggregate precoating material.
up to a week after application may result in the aggregate
stripping. Spraying should not be undertaken if wet 6.2.4 Aggregate Precoating
weather is predicted within several days after application. It is important to only use aggregate that is of good quality and
• Adhesion agent should be added to the PMB in the that is dry and free from dust. It is also important to adhere to
sprayer no more than half an hour prior to spraying and recommended cutting practice. This applies to all PMB seals,
the load thoroughly circulated. Exceptions may apply to including those applied on lower traffic volume roads. However,
a few specific ‘heat stable’ adhesion agents known to initial adhesion of PMB to the aggregate particles may still be
retain effectiveness after several hours at high difficult to achieve, especially with increasing concentrations of
temperatures. Such materials should only be used in polymer and rubber crumb. It is therefore essential to precoat
accordance with the supplier’s recommended maximum the aggregate, preferably with a bitumen-based precoat that
temperature and storage times. contains about 1% of adhesion agent. This should ensure both
• The PMB/aggregate/precoating material/adhesion agent effective initial adhesion and longer term retention of the
system should be evaluated, well in advance of the work, aggregate.
using both the initial adhesion and plate stripping tests.
Check with the manufacturer if unsure of the details.
• Cutter oils are generally required to facilitate spraying of
PMBs and wetting of aggregate.
• Some of the more viscous PMBs will require the use
of larger spray nozzles; e.g. B6 or B8 nozzles, depending
on binder viscosity, to ensure a uniform transverse binder
application.

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.

GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS 10


REFERENCE
AAPA (1998) Advisory Note 14 Summary of SBS Bitumen Fume
Monitoring Project.

AAPA (1998) HS&E Guide No 5 Guide to the safe use of SBS.

AAPA (2004) Advisory Note 7 Guide to the Heating and Storage


of Binders for Sprayed Sealing and Asphalt Manufacture.

AUSTROADS (2000) AP-T42/06 Guide to the Selection and Use


of Polymer Modified Binders and Multigrade Bitumens.

AUSTROADS (2006) AG:PT/T101 Method of Sampling Polymer


Modified Binders, Polymers and Crumb Rubber.

AUSTROADS (2008) AG:PT/T102 Protocol for Handling


Modified Binders in Preparation for Laboratory Testing.

AUSTROADS (2008) AP-G41/08 Austroads Bituminous Materials


Safety Guide.

AUSTROADS (2010) AGPT/T190 Specification Framework for


Polymer Modified Binders and Multigrade Bitumens.

AUSTROADS/AAPA (1998) Pavement Work Tip No. 13


Temperature Characteristics of Binders in Asphalt.

AUSTROADS/AAPA (2001) Pavement Work Tip No. 27 Sprayed


Sealing – Cutting Back of Polymer Modified Binders.

NOHSC:2011(2003) National Code of Practice for the


Preparation of Material Safety Data Sheets 2nd Edition.

Austroads test methods and selected Austroads Technical


Reports may be accessed and downloaded, free of charge,
from the Austroads web-site at www.austroads.com.au.

AAPA Advisory Notes, HS&E Guides, and Austroads/AAPA


Work Tips may be accessed and downloaded, free of charge,
from the AAPA web-site at www.aapa.asn.au.

GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS 11


GLOSSARY

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.

crumb rubber – Rubber particles manufactured from waste or


reclaimed rubber products such as vehicle tyres and graded to
conform to a specified size range. Used in bitumen to improve
binder properties.

cutback bitumen – Bitumen to which cutter oil (kerosene) has


been added to achieve a temporary reduction in viscosity.

cutter (kerosene) – A light petroleum distillate added to


bitumen to temporarily reduce its viscosity (cutback bitumen).
A high-flash cutter is a cutter with a flash point above 60°C.

material safety data sheet (MSDS) – A document that


provides health and safety information about products,
substances or chemicals that are classified as hazardous
substances or dangerous goods.

multigrade bitumen – A bituminous binder which, at high


service temperatures shows good resistance to flow, and at low
temperatures does not exhibit the high stiffness (leading to
brittleness) normally experienced with conventional bitumen
binders.

GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS 12


The Australian Asphalt Pavement Association is a non-profit
organisation formed to promote the economic use of asphalt and
bitumen bound products based on sound technical and commercial
grounds.

Throughout its history, AAPA has maintained as its major objective


thedissemination of technical knowledge aimed at continual
improvement in Asphalt technology.

AAPA Members include manufacturers of asphalt and other bitumen


bound products, State Road Authorities, Local Government,
pavement engineering consultants, material suppliers, plant and
machinery manufactures paving and sealing contractors and
individuals interested in asphalt technology.

Level 2, 5 Wellington Street


Kew Victoria 3101 AUSTRALIA

Telephone: (03) 9853 3595


Fax: (03) 9853 3484
Email: info@aapa.asn.au
Web: www.aapa.asn.au

GUIDE TO THE MANUFACTURE, STORAGE AND HANDLING OF POLYMER MODIFIED BINDERS

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