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Project Manager
Steve Brown, VicRoads
Prepared by
Bituminous Surfacing Research Reference Group
ARRB Transport Research Ltd
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:
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.
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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Austroads 2005
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Geotextile Reinforced Seals
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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Austroads 2005
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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
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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2. APPLICATIONS
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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.
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.
3.2 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.
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).
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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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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.
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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.
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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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7.2 Spraying
It is accepted practice that the edges of the geotextile are covered by the seal.
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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.
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.
7.5 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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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.
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8. LINE MARKING
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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
KEYWORDS:
ABSTRACT: