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Geotextile Reinforced Seals


AUSTROADS TECHNICAL REPORT
AP-T37/05
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Geotextile Reinforced Seals


Geotextile Reinforced Seals
First Published 2005

© Austroads Inc. 2005

This work is copyright. Apart from any use as permitted under the Copyright Act 1968,
no part may be reproduced by any process without the prior written permission of Austroads.

National Library of Australia


Cataloguing-in-Publication data:

Geotextile Reinforced Seals


ISBN 1 921139 11 0

Austroads Publication No. AP–T37/05


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Project Manager
Steve Brown, VicRoads

Prepared by
Bituminous Surfacing Research Reference Group
ARRB Transport Research Ltd

Published by Austroads Incorporated


Level 9, Robell House
287 Elizabeth Street
Sydney NSW 2000 Australia
Phone: +61 2 9264 7088
Fax: +61 2 9264 1657
Email: austroads@austroads.com.au
www.austroads.com.au

Austroads believes this publication to be correct at the time of printing and does not accept
responsibility for any consequences arising from the use of information herein. Readers should
rely on their own skill and judgement to apply information to particular issues.
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Sydney 2005
Geotextile Reinforced Seals
Austroads profile
Austroads is the association of Australian and New Zealand road transport and traffic authorities
whose purpose is to contribute to the achievement of improved Australian and New Zealand road
transport outcomes by:
„ undertaking nationally strategic research on behalf of Australasian road agencies and
communicating outcomes
„ promoting improved practice by Australasian road agencies
„ facilitating collaboration between road agencies to avoid duplication
„ promoting harmonisation, consistency and uniformity in road and related operations
„ providing expert advice to the Australian Transport Council (ATC) and the Standing Committee
on Transport (SCOT).

Austroads membership
Austroads membership comprises the six state and two territory road transport and traffic
authorities and the Commonwealth Department of Transport and Regional Services in Australia,
the Australian Local Government Association and Transit New Zealand. It is governed by a
council consisting of the chief executive officer (or an alternative senior executive officer) of each
of its eleven member organisations:

„ Roads and Traffic Authority New South Wales


„ Roads Corporation Victoria
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„ Department of Main Roads Queensland


„ Main Roads Western Australia
„ Department for Transport, Energy and Infrastructure South Australia
„ Department of Infrastructure, Energy and Resources Tasmania
„ Department of Planning and Infrastructure Northern Territory
„ Department of Urban Services Australian Capital Territory
„ Australian Department of Transport and Regional Services
„ Australian Local Government Association
„ Transit New Zealand

The success of Austroads is derived from the collaboration of member organisations and others in
the road industry. It aims to be the Australasian leader in providing high quality information, advice
and fostering research in the road sector.

Bituminous Surfacings Research Reference Group


„ Ray Gaughan, Roads and Traffic Authority New South Wales (Convenor)
„ John Esnouf, VicRoads
„ Walter Holtrop, Australian Asphalt Pavement Association
„ Phillip Phillips, Geofabrics Australasia P/L
„ John Lysenko, Pioneer Road Services
„ Sam Grasso, Pioneer Road Services
„ George Fannelli, Ten Cate Nicolon Aust.
„ Allan Alderson, ARRB Group.
Geotextile Reinforced Seals

EXECUTIVE SUMMARY

This report has been prepared to assist users in the correct application, design and maintenance
of geotextile reinforced seals (GRS).
A GRS consists of a bond (tack) coat sprayed on to the existing surface over which a geotextile
fabric is placed and rolled into close contact. A further application binder is applied and a single
sized aggregate spread and rolled into the second binder application. In some instances additional
binder and sealing aggregate may be applied to produce a double/double GRS.
The fabric is incorporated to add strength to the treatment. A geotextile can be incorporated into
any seal design and is most often used as a surfacing treatment but has been used successfully
as an interlayer
Two ranges of fabric are discussed and include recommended properties.
Included in the discussion are the type of plant that should be used to ensure uniform and correct
application of a GRS.
The report concludes with some discussion on the need to undertake the work in a timely manner,
what maintenance strategies have been proven to work and finally processes to recycle a GRS at
the end of its useful life.
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CONTENTS

Page

1 INTRODUCTION ......................................................................................................................1
2. APPLICATIONS .......................................................................................................................2
2.1 Sprayed Seals .................................................................................................................2
2.2 Composite Treatments ....................................................................................................2
3. MATERIALS.............................................................................................................................3
3.1 Geotextiles ......................................................................................................................3
3.2 Binders ............................................................................................................................3
3.3 Aggregates 3
4. SEAL DESIGN .........................................................................................................................4
4.1 Seals or Reseals .............................................................................................................4
4.2 Composite Treatments ....................................................................................................4
4.3 Aggregate Sizes ..............................................................................................................4
4.4 Fabric Selection...............................................................................................................4
5. PRE-SEALING CONSIDERATIONS........................................................................................6
5.1 Stabilised Heavy Duty Pavements ..................................................................................6
5.2 Texture Correction...........................................................................................................6
5.3 Pre-spraying of Untrafficked Areas .................................................................................6
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6. OPERATIONS ..........................................................................................................................7
6.1 Sequence of Operations..................................................................................................7
6.2 Surface Preparation ........................................................................................................7
6.3 Weather Conditions .........................................................................................................8
7. OPERATIONS ..........................................................................................................................9
7.1 Equipment ......................................................................................................................9
7.2 Spraying ........................................................................................................................10
7.3 Placement of Geotextile ................................................................................................11
7.4 Aggregate Spreading and Rolling .................................................................................11
7.5 Trafficking......................................................................................................................11
7.6 Reduced Daily Production .............................................................................................12
8. LINE MARKING .....................................................................................................................13
8.1 Clay Pavements ............................................................................................................13
8.2 Other Pavements...........................................................................................................13
9. MAINTENANCE .....................................................................................................................14
10. RECYCLING...........................................................................................................................15

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TABLES
Table 1: Geotextile Properties .........................................................................................................3
Table 2: Typical Sequence of Operation for Geotextile Reinforced Seals.......................................7

FIGURES
Figure 1: Geotextile Reinforced Seal ................................................................................................1
Figure 2: Schematic of a Fabric Spreader ........................................................................................9
Figure 3: Example of a Fabric Spreader in operation1 ...................................................................10
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Geotextile Reinforced Seals

1 INTRODUCTION
This guide provides the road practitioner with useful information on the use, design, application
and maintenance of geotextile reinforced seals (GRS). It should be used in conjunction with other
Austroads and State Road Authority guides for Sprayed Sealing.
GRS are an effective sprayed sealing technique for treating badly cracked and distressed
pavements (bound and unbound), particularly where the crack movements are slow.
A GRS is produced by (see also Figure 1):
1. Spraying a layer of bitumen (bond [tack] coat) on to the existing surface
2. Covering the bond coat with an approved fabric and lightly rolling to ensure good adhesion of
the fabric
3. Application of binder
4. Spreading a sealing aggregate
5. Rolling to ensure good adhesion of the aggregate to the fabric.
In some instances additional binder and sealing aggregate may be applied to produce a
double/double GRS.
The fabric is incorporated to add strength to the treatment and provide a seal to cope with
pavement conditions where conventional binder or polymer binder seals are known to have a
reduced life. A geotextile can be incorporated into any seal design.
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Sealing aggregate
Second binder application
Geotextile
First binder application
Weak or cracked base

Figure 1: Geotextile Reinforced Seal

Geotextile reinforced sprayed sealing treatments, in common with all sprayed sealing techniques,
do not affect the shape or ride of the pavement. They can, however, be applied on top of other
surfacings.

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Geotextile Reinforced Seals

2. APPLICATIONS

2.1 Sprayed Seals


GRS provide a strengthened waterproof membrane suitable for applications such as a strain
alleviating membrane (SAM) over cracked pavements, including asphalt and sealed surfaces and
as a wearing surface for expansive clay pavements where conventional and polymer binders are
known to have a reduced life. The use of a fabric, as well as adding strength to the seal, allows for
an increased application of bitumen and hence improved waterproofing.
GRS are not recommended for high stress locations. High stress locations are those where the
traffic forces on the pavement are increased due to acceleration, braking or turning. Common
locations include intersections, junctions, roundabouts, curves and industrial entrances.

2.2 Composite Treatments


GRS can also be used as a strain alleviating interlayer (SAMI) under other surfacing treatments,
such as asphalt to provide additional waterproofing or delay reflective cracking from the underlying
pavement. To minimise the risk of debonding of asphalt placed on a GRS, it is recommended the
GRS should be trafficked until it is firmly bonded to the base structure prior to placement of the
asphalt. The length of time that a GRS can be trafficked may be restricted by the location and
service conditions.
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3. MATERIALS
3.1 Geotextiles
Geotextiles used for sprayed sealing are conventionally manufactured from polymers, the most
frequently used being polyester and polypropylene. The fabric should be non-woven, needle-
punched and formed from mechanically entangled filaments. Geotextiles made from continuous
filaments are preferred.
Geotextiles typically have the properties shown in Table 1.

Table 1: Geotextile Properties


Property Recommended Minimum
Light Fabric Grade Heavy Fabric Grade
Mass (g/m2) 130 175
Thickness (mm) 1.5 1.8
Elongation at ultimate strength (%) 50 50
G Value (Robustness) 950 950
Bitumen saturation (L/m2 ) 0.9 1.1
Melting Point (oC) 165 165
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A minimum fabric mass of 130 g/m2 is recommended for sealing applications. However, when a
GRS is used on expansive clays or untreated soft pavements, and larger sized sealing aggregates
(e.g. > 10 mm) are proposed, a heavier grade of fabric with a fabric mass of ≥175 g/m2, should be
used to reduce the risk of puncturing of the fabric.

3.1.1 Storage and Handling of Geotextiles


Geotextile fabrics should be stored in dry areas, in their shipping bags, and away from direct
sunlight for protection from moisture infiltration and UV degradation.
The core of the fabric roll should be a smooth bored PVC pipe and not cardboard. Cardboard
cores are more likely to crush during handling, particularly if affected by moisture.
A wet geotextile fabric should not be used as the potential for aggregate stripping is increased.

3.2 Binders
Conventional sealing binders, usually C170 bitumen and/or polymer modified binders can be used
for a GRS. Current practice has been to mainly use C170 bitumen.
Bitumen emulsions and polymer modified bitumen emulsions have also been used successfully in
GRS applications.

3.3 Aggregates
Aggregate should be as used for conventional sealing operations and conform to the relevant
State Road Authority or other appropriate specification. Aggregate should be precoated prior to
use. Wet cover aggregate containing free water must not be used.

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4. SEAL DESIGN
4.1 Seals or Reseals
GRS (seals or reseals) are designed in accordance with conventional seal design procedures
(Austroads, 2002). Allowances are then added for binder retention by fabric and binder absorption
by base, (if not primed or primersealed). The allowance for binder absorption by base is usually
between +0.1 and +0.4 L/m2. This may be assessed using Austroads Test Method SDT 05.
The “binder retention by fabric allowance” (according to ASTM D6140-00) is the volume of bitumen
required to saturate the fabric and varies from 0.8 to 1.3 L/m2 (cold) of binder, depending on the
thickness of the geotextile.
The allowance for retention of the binder by fabric should be calculated using:
„ Material thickness (mm) under 2 kPa pressure (AS3706.1-90)
„ Unit Mass (g/m2) of fabric (processed material)
„ Specific gravity (g/m2) of unprocessed material.
The Roads and Traffic Authority of New South Wales have developed a draft test method (T654)
which details this process.

4.2 Composite Treatments


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The seal component of a composite treatment is designed as described above in section 4.1.
Care is required in the selection of the type of overlay used in the composite treatment. Types of
overlay used successfully to date include:
„ Dense-graded asphalt
„ Stone mastic asphalt
„ Open-graded asphalt
„ Ultra-thin open-graded asphalt
„ Slurry surfacings.
Due to the specialised nature of composite treatments expert advice should be sought if proposing
these types of treatments. In considering a composite treatment, provision should also be made
for rehabilitation and recycling strategies at the end of the life of the surfacing (see additional notes
in section 10).

4.3 Aggregate Sizes


It is preferable to use only 10 mm or larger aggregate for single/single GRS treatments as smaller
aggregates (i.e. 5 and 7 mm) have a tendency to flush or bleed in GRS applications. Aggregate
sizes 5 and 7 mm are acceptable for use in double/double applications as the second layer.
Aggregates larger than 10 mm have an increased potential for puncturing the fabric and this
should be considered when selecting the fabric.

4.4 Fabric Selection


A minimum fabric mass of 130 g/m2 is used for general sealing applications with 10 mm ggregate.
Where larger sealing aggregates are proposed, heavier grades of fabric (175 to 200 g/m2) should
be used.

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Geotextile Reinforced Seals

Geotextiles made from polyester are preferred when using hot bitumen as they have a higher
melting point. Where polypropylene fabric is used the binder temperature should not exceed
170°C.
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Geotextile Reinforced Seals

5. PRE-SEALING CONSIDERATIONS
Pre-sealing requirements for GRS are the same as for conventional seals. The usual rules for
good surface preparation and sealing practices apply (see Austroads, 2004). This will ensure the
maximum effective life for the treatment.

5.1 Stabilised Heavy Duty Pavements


For stabilised pavements in heavy duty conditions (e.g. > 1x107 ESAs or exceeding 500 v/l/d), the
surfacing must be primersealed, primed and sealed or sealed prior to application of the GRS. This
will more effectively anchor the GRS to the base. This also ensures that a rough interface
(assumed in a Circly design) is achieved for both retention of the seal under traffic and to avoid a
slip layer under future asphalt overlays.

5.2 Texture Correction


Where the existing surface texture is too coarse for the proposed GRS aggregate or irregular,
then a correction course comprising a small sized aggregate seal or reseal, should be applied well
in advance of a GRS.
Where the existing surface is smooth, with little or no texture, or is recently applied asphalt or
slurry surfacing, then a small sized aggregate seal should be applied at least six weeks in advance
to provide a friction key for the GRS.
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5.3 Pre-spraying of Untrafficked Areas


Untrafficked areas, (along the centreline, outer edges and between wheel tracks), may be pre-
sprayed with 0.2 to 0.3 L/m2 bitumen (usually C170) in advance of the bond coat or after the
application of the geotextile, particularly if the texture is more hungry in those areas.

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Geotextile Reinforced Seals

6. OPERATIONS
6.1 Sequence of Operations
A typical order of operations is shown in Table 2. There may be slight variations to this order for
particular circumstances, e.g. if the bond coat bleeds through the geotextile, a 7 mm aggregate
may need to be spread prior to or during rolling of the geotextile.

Table 2: Typical Sequence of Operation for Geotextile Reinforced Seals


Order of Operations Operation
1 Surface preparation
2 Bond (tack) coat
3 Apply geotextile
4 Roll geotextile
5 Spray binder
6 Apply aggregate
7 Roll aggregate
For a double/double seal the second application would be applied in
8
the normal manner
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6.2 Surface Preparation


For natural surface or clay formations, the relative compaction of the pavement should comply with
the appropriate specifications.
Preferred practice for unsealed bases is to first apply a prime or primerseal. Priming is
recommended where a GRS is to be applied to a granular or modified pavement (particularly
stabilised), timber or concrete surfaces.
Before spraying, the surface should be cleaned, swept and given a light spray with water (if not
primed or primersealed) to promote penetration.
GRSs are used to treat pavements that have the potential to, or are already, extensively cracked
without any pretreatment, provided the cracks are less than 3 mm in width. Larger cracks should
be pretreated with one or a combination of the following:
„ Fill with emulsion and grit
„ Hot or cold modified bitumen crack sealants. (When using this method cracks should be
filled but not overbanded)
„ Fine asphalt or slurry mixes.
Other defects, e.g. ruts, potholes, shoving, edge defects, etc., should be repaired before resealing.
As a general rule, any correction seal, crack filling and pavement repairs should be completed at
least six weeks in advance of the application of the GRS to reduce the risk of bleeding or flushing.

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Geotextile Reinforced Seals

6.3 Weather Conditions


GRS are specialised treatments and should only be placed in dry warm conditions. Preferred
conditions are:
„ Minimum air and pavement temperatures should be:
− Class 170: > 15 °C and rising
− PMBs: > 20 °C and rising
„ Predicted fine weather for next few days
„ Little or no wind (to reduce billowing of fabric)
„ Pavement dry
„ Surface dry to avoid trapping moisture under the GRS.
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Geotextile Reinforced Seals

7. OPERATIONS

7.1 Equipment
The plant used for conventional sprayed sealing operations can be used for geotextile reinforced
sealing. The use of pneumatic-tyred multi-wheel rollers of less than 15 t mass is preferred to
lessen the risk of embedment of aggregate and/or crushing the aggregate.
In addition, a fabric applicator such as the one shown in Figure 2, is required. This is usually a
lightweight frame attached to a loader (smaller, non-articulated loaders are preferred), or other
similar plant item, with a spindle to hold the roll of geotextile. A spring-loaded broom arrangement
and/or tensioning bar is attached at the base of the frame to press the fabric firmly onto the
pavement surface to prevent wrinkling. There should be a special tension control mechanism to
ensure a uniform fabric tension during application.
Frames can be manufactured locally or can usually be hired or purchased from geotextile
suppliers.
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Figure 2: Schematic of a Fabric Spreader

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Geotextile Reinforced Seals

Figure 3: Example of a Fabric Spreader in operation


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7.2 Spraying
It is accepted practice that the edges of the geotextile are covered by the seal.

7.2.1 Bond (tack) coat


The binder used for a bond coat is usually a C170 bitumen, ideally without cutter oil. Where the
pavement material is relatively permeable, and where priming or primersealing has not been
carried out in advance, a small amount of cutter oil (up to 3%) may be used in the bond coat to
promote penetration. If too much cutter oil is used in the bond coat (e.g. >3%) the evaporation of
volatiles will be slow, and in hot weather this can cause bubbling in the sealed surface.
The bond coat binds the fabric onto the road surface during sealing and the application rate used
ranges between 0.4 and 1.0 L/m2 (cold).
The amount of bond coat applied is part of the total design binder application rate.
The bond coat should be sufficient to secure the fabric during application and sealing operations,
without causing the binder to bleed through the fabric during placement or subsequent rolling.
Ideally, cutter oil should not be used in bond coats over impermeable pavements such as clay
pavements or heavily bound base materials, as the cutter oil will be trapped in the geotextile,
leading to softening of the seal and possible aggregate stripping. The bond coat should be
sprayed wider than the width of the geotextile to be laid, to allow the final seal to protect the edges
of the geotextile.
If the geotextile is to be placed in two or more adjacent runs, the bond coat should be sprayed one
run at a time, prior to placing each run of geotextile. The overlap width for the geotextile should be
about 100 to 200 mm and must be fully saturated with bitumen to minimise the potential for
aggregate stripping along the join. To achieve this, the overlap area is sprayed twice – the second
spray run overlapping the first run of geotextile.

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Geotextile Reinforced Seals

7.2.2 Seal
The binder is usually Class 170 bitumen and may be cutback as per normal sealing practice. It
should be sprayed onto the geotextile at GRS design rate following placement of the geotextile.
Bitumen should not be sprayed onto the geotextile if the geotextile has become wet, as the
presence of moisture will lead to subsequent seal loss. For this reason, sealing should not
commence unless the seal over the geotextile can be applied well before any rain or inclement
weather occurs.

7.3 Placement of Geotextile


The geotextile should be rolled out slowly (using a fabric applicator) immediately after spraying the
bond coat, and as close behind the sprayer as practicable.
The unfurling fabric should be kept as low as possible to the ground to prevent billowing and
should be kept taut to minimise wrinkling. Wrinkles should be broomed out, or cut and butted
where necessary.
Adjoining or adjacent rolls should be overlapped by 100 to 200 mm, with the overlapped join
receiving additional binder as described above. Placing of fabrics along straight alignments is
generally problem free.
Where the geotextile is to be placed around a significant curve, it should be ‘cut and butted’ at
regular intervals along the inner side of the curve. Any overlaps should be hand sprayed with
additional bitumen so that the geotextile is fully saturated. Wrinkles larger than 25 mm should be
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treated as overlaps.
Care must be taken to ensure overlaps do not occur in the wheel path areas.
On clay formations, the fabric should be laid as wide as possible over the shoulder area of the
pavement, to prevent shoulder erosion and ingress of moisture. For other applications, the fabric
should be applied over the full width of the pavement or trafficked lane width, as appropriate.
The fabric should be lightly rolled prior to the application of binder.
If rolling and/or construction traffic causes the bond coat to bleed up through the fabric, a blinding
coat of 7 mm aggregate may be applied in advance of sealing to prevent pick-up.
Rollers or vehicles should not stand on the laid fabric as this may lead to a build-up of binder on
the surface of the fabric.

7.4 Aggregate Spreading and Rolling


Aggregate should be spread onto the binder as soon as possible after spraying. Rolling should be
carried out with a rubber tyred roller with the rolling sequence being from the middle outwards to
the edges.

7.5 Trafficking
Traffic can be used to assist with compaction of the GRS as in conventional sealing practices.
For double/double treatments, slow moving traffic should be allowed onto the GRS after the first
layer of aggregate has been placed. Speed restrictions may be required until the aggregate and
binder are firmly adhered to the geotextile.
For treated pavements, trafficking of the fabric (i.e. no aggregate cover) may be permitted in
extreme circumstances such as plant breakdowns and emergencies, provided traffic speeds are
kept low and the time of trafficking is minimised.

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Geotextile Reinforced Seals

CAUTION
If the exposed fabric becomes wet (unexpected storm or accident) the surface becomes
very slippery and trafficking should be halted immediately and not recommenced until the
surface is completely dry. Where practical, a physical barrier should be erected to prevent
trafficking of the wet, exposed fabric.

7.6 Reduced Daily Production


When programming GRS operations, allowance may be made for reduced area compared to
normal sealing works. This is due to the additional requirements for the application of the bond
coat and geotextile and the additional rolling requirements.
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Geotextile Reinforced Seals

8. LINE MARKING

8.1 Clay Pavements


On lightly trafficked roads only the edge lines should be painted. This will reduce the likelihood of
rutting.
Appropriate signs indicating no centre line marking and no overtaking on crests and curves should
be erected.
At any locations with less than overtaking sight distance, the line marking should be as for a
normal two lane road with marked centre line.

8.2 Other Pavements


For other pavements, there are no special requirements and line marking can be undertaken as for
conventional sprayed seals.
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Geotextile Reinforced Seals

9. MAINTENANCE
For information regarding the maintenance of GRS on clay pavements see the Roads and Traffic
Authority publication “Maintenance of Geotextile Reinforced Seals on Clay Pavements”.
Where a clay pavement surfaced with a GRS has been subjected to flooding, it should be allowed
to dry back prior to reopening to traffic. It should then be rolled with a pneumatic tyred multi tyred
roller from the inside (centre of pavement) to the outside before being opened to traffic. Premature
opening, particularly to heavy vehicles and four wheel drives, is likely to cause debonding of the
GRS from pavement and pavement deformation.
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Geotextile Reinforced Seals

10. RECYCLING
A GRS asphalt pavement intended to be recycled as reclaimed asphalt pavement (RAP) must be
removed by cold planing. It should be noted that there is limited experience with recycling of GRS
pavements.
RAP containing polyester type geotextiles may be more difficult to recycle because of the high
melting point of polyester (250oC). RAP is recycled by being added to heated aggregates prior to
the addition of bitumen. The aggregates are generally heated to a maximum of 200oC and as such
the polyester will remain at temperatures below its melting point. This may make asphalt produced
with RAP containing polyester geotextiles difficult to pave and compact.
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Geotextile Reinforced Seals

BIBLIOGRAPHY
AUSTROADS (2002). Practitioners Guide to design sprayed seals – Revision 200 Method. Austroads
Publication No. AP-T17, (ARRB Transport Research , Melbourne).

AUSTROADS (2004). Sprayed sealing guide. Austroads Publication No. AP-G76/04, (ARRB Transport
Research , Melbourne).

ROADS AND TRAFFIC AUTHORITY (1992). Guide to the design, construction, maintenance and
management of clay pavements with geotextile reinforced seals. RTA Document No. GS-116-1092
(Sydney, RTA).

ROADS AND TRAFFIC AUTHORITY (1997). Geotextile reinforced seals. RTA Preferred practice 97/3
(Sydney, RTA).
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INFORMATION RETRIEVAL

Austroads (2001), Geotextile Reinforced Seals, Sydney, A4, 25pp,


AP-T37/05

KEYWORDS:

Sprayed seal, geotextile, geotextile reinforced seal, clay pavement, interlayer,


surfacing

ABSTRACT:

This guide presents information on the application, design, maintenance and


recycling of geotextile reinforced seals. The main application is as a surfacing
treatment though there is some discussion of use as an interlayer. Two
grades of fabric are recommended for use and typical properties are provided.
Construction technique plays a roll in achieving a satisfactory result and
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appropriate equipment is discussed.

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