SEAL DESIGN

1 Introduction
 South African Surfaced Road Network

• Surfaced
(200 000km)
• Unsurfaced
(600 000km)
• Seals = > 80%

Introduction
 TRAFFIC DISTRIBUTION
PROCLAIMED SURFACED RURAL ROADS
(South Africa)
14000
12000 Seals Asphalt
10000
8000
km

6000
4000
2000
0
0

0
0

0
00

00

00
20

50

00
00

00

00

00

00
10

00

00
0-

0-

00
-2

-4

-6

20

50
0-

-1

10
20

>1
00

00

00

0-

0-
50

00

0-
10

20

40

00

00
60

00
10

20

50
VEHICLES PER DAY(both directions)
 Road Pavements in South Africa

bituminous
kerb
surfacing
side walk (3mm – 50mm)

base (>90% granular)

sub-base (granular or cemented) pavement

structure

selected (granular)

FILL OR IN SITU MATERIAL

Comparison of pavement structures

Crushed stone
BTB
Cement Stabilised

Selected natural Selected natural

gravel gravel
Selected natural
gravel
Insitu material
Insitu material
 Surfacing Seals

Spray bituminous binder

Spread single-sized
aggregate
Rolling
 Definition

• A Single Surfacing seal is:

– product of application of a SPRAYED
bituminous binder
– and application of SINGLE SIZED
aggregate to the pavement”
– to
• provide a durable, all weather, skid resistant
riding surface
• Seal, protect, waterproof the base
 Typical Seals used in SA

single seal

double seal

double seal (1.5)

cape seal
 Typical Seals used in SA

geotextile seal

split seal

choked seal

inverted seal
 Typical Seal Types

slurry seal

grit/ sand seal

graded aggregate/ Otta seal

 Seal Type Distribution
(Western Cape 6 – year average)

Asphalt, 2%
Rejuvenation, Double seals,
13% 5%

Slurry Seals,
7%

Sand seals, Single seals,

22% 51%
 Seal Type Distribution
(SANRAL 2006)
Single seals,
10%
Asphalt, 15%

Cape Seal,
10%

Double Seals,
65%
Development of Seal design methodologies
• Late 1930s
• Hansen’s theory of filling voids (1935)
• NDOT, 4 Provinces – each own method
• Significant research 70s
– Relating embedment to Ball penetration
– Rational seal design method (Not well accepted by
practitioners)
– TRH3 (1984) – compendium of designs
• Ad hoc studies – improvements to own methods
• Appropriate standards for low volume roads – 1993
(SABITA)
• TRH3 (1998)
Development of Seal design methodologies
• TRH3 (1998)
– Road authorities’ and consultant’s experience incorporated

Road authorities’ recommended applications

High

Maximum for target texture

Binder
application
Minimum
Low

Traffic Max

– Improvements to rational design method Min

30%

– Modified binders incorporated

 Development of Seal design
methodologies
• Numerical behavioural model (T Milne)
– Loading on a textured surface
Tyre Tyre
Inflation Inflation
Pressure Pressure
P P

σ Bulk σ Micro

σ = Bulk Stress σ = Micro Stress

Run 3 : SBS : Round Stone : Bitumen Interface

Displacement Top of Centre Stone

7.00

6.00

Fbulk Fmicro 5.00

Smooth or closely Textured 4.00

Displacement (mm)
packed asphalt seal stone surface 3.00
surface
2.00

1.00

0.00

σ Bulk < σ Micro -1.00

1 22 43 64 85 106 127 148 169 190 211 232 253 274 295 316 337 358 379 400 421 442 463 484 505 526 547

F Bulk = F Micro 7 .0 0

6 .0 0
Ru
n 3 : S BS : Ro
Di s
u n d S to n e :B it u me
p la c e
nI n
t e
r fa c e
me n tT o p o fC e n tre S t o
ne

7 .0 0

6 .0 0
Ru n 3 : S
BS : Ro u n
D is p
l a
d St o
c e me
n e : B itu me n In te r fa c
nt To
p o f Ce
n t re S to n e
e

7 .0 0

6 .0 0
Ru
n 3 : S BS : Ro

Di s
u n d S to n e :B it u me

p la c e
nI n
t e
r fa c e

me n tT o p o fC e n tre S t o
ne

7 .0 0

6 .0 0
Ru n 3 : S
BS : Ro u n
D is p
l a
d St o
c e me
n e : B itu me n In te r fa c
nt To
p o f Ce
n t re S to n e
e

Displacement (mm)
5 .0 0

5 .0 0 5 .0 0 4 .0 0 5 .0 0

Displacement (mm)

Displacement (mm)
Displacement (mm)
4 .0 0 4 .0 0 3 .0 0 4 .0 0

3 .0 0 3 .0 0 2 .0 0 3 .0 0

2 .0 0 2 .0 0 1 .0 0 2 .0 0

1 .0 0 1 .0 0 0 .0 0 1 .0 0
1 2 2 4 3 6 4 8
5 0 6 1
1 2 7
1 4
8 1 6
9 1 9
0 2
1 1 2
3 2 2
5 3 2
7 4
2 9 5
3 1
6 3 3
7 3 5
8 3
7 9 4
0 0 4
2 1 4 2
4 6
3 4 8
4 5 0
5 5 2
6 5
4 7
0 .0 0 0 .0 0 -1 .0 0 0 .0 0

1 2 2 4 3 6 4 8
5 0 6 1
1 2 7
1 4
8 1 6
9 1 9
0 2
1 1 2
3 2 2
5 3 2
7 4
2 9 5
3 1
6 3 3
7 3 5
8 3
7 9 4
0 0 4
2 1 4 2
4 6
3 4 8
4 5 0
5 5 2
6 5
4 7 1 2 4 3 6 4 8 5 1
0 6 1
2 7 1
4 8 1
6 1
9 9 2
0 1 2 3
2 2 5
3 2 7
4 2 9
5 3
1 6 3 7 3
5 8 3
7 9 4
0 4
0 2
1 4 4
2 4 6
3 4 8
4 5
0 5 5
2 6 5
4 7 1 2 4 3 6 4 8 5 1
0 6 1
2 7 1
4 8 1
6 1
9 9 2
0 1 2 3
2 2 5
3 2 7
4 2 9
5 3
1 6 3 7 3
5 8 3
7 9 4
0 4
0 2
1 4 4
2 4 6
3 4 8
4 5
0 5 5
2 6 5
4 7
-1 .0 0 -1 .0 0 -2 .0 0 -1 .0 0
T im e S te p O
f F
r o
n t A
n d B
a c k
A x le

-2.00
-2 .0 0 -2 .0 0 D is p
la c
e me
n tL a
t e
ra l is p la
D c e
me n
t L
o n
g itu d
i n
a l D is p
la c e
men t V
e rti c
a l -2 .0 0
T im e S te p O
f F
r o
n t A
n d B
a c k
A x le i me S
T te p O fF ro n tA n
d Ba c
k Ax
l e i me S
T te p O fF ro n tA n
d Ba c
k Ax
l e

D is p
la c
e me
n tL a
t e
ra l is p la
D c e
me n
t L
o n
g itu d
i n
a l D is p
la c e
men t V
e rti c
a l D is p
l a
c e
men t L
a te ra
l D is
p la c
e me
n tL o
n g
i tu
d in a
l D is
p la c
e me
n tV e rtic a
l D is p
l a
c e
men t L
a te ra
l D is
p la c
e me
n tL o
n g
i tu
d in a
l D is
p la c
e me
n tV e rtic a
l

Time Step Of Front And Back Axle

Displacement Lateral Displacement Longitudinal

Introduction Displacement Vertical
 Current studies on PMS data
Condition
Rate of deterioration dependent on
Index
• Type of surfacing
• Condition before treatment
100 Immediate • Traffic etc.
improvement

VCIt
50

Effectiveness = (Area above – Area beneath) x ADT x Length

0
Time (years)
 TRH 3 Guideline document

• Part of TRH document series

• Collate existing South African practice
– Guidelines (not specifications)
– Aimed at the average engineer (80/20)
– Applicable only within range of experience
– Highlights limitations and risks
• TRH3 (2007)
 TRH 3 (2007)
Scope of the document
• Background to sealwork
• Investigation & seal type selection
• Pre-treatment
• Design
– Conventional and modified binder
– Sand seals, Single & Double seals,
– Slurry and Cape seals
– Fogspray and rejuvenators
– Geotextile seals
– Graded aggregate seals
• Construction and quality control guidelines
• Labour intensive sealing
• Maintenance
 MAIN CHANGES

• Modified binder seals (single and double)

– Change in principles
• Addition of combination binder seals
– Specifically 19/6,7 split seal
• Several additional practical hints
• Changes to design graphs (min and max)
• Additional seals included
– Otta seal/ graded aggregate seals
Bituminous Binders
Crude Oil Source
… bituminous binders
Crude Oil to Finished Product
… bituminous binders
(repeat bpk1)
Differences Between Crudes
… bituminous binders

Sourakhany Arabian Barrow Island,

Light Australia
Differences Between Crudes
… bituminous binders

Boscan Altamount Minas

 Crude Oil
… bituminous binders

1 Barrel of crude oil is equivalent to

158.98 L and comprised of:
– 43,4% Gasoline
– 37,4% Fuel oil
– 4,3% Kerosene
– 2,3% Jet fuel
– 2% Lubricants
– 1,3% Petrochemicals
– 9,3% Other
 Refinery Operations
… bituminous binders
• The crude oil is injected into the
distillation column at high
temperatures
• This causes the crude to boil and
evaporate
• In the column, condensation and re-
evaporation take place on a
continuous basis (scrubbing) as the
vapor ascends
• Fractions with the required boiling
range are continuously withdrawn
from appropriate points in the
column, the highest (most volatile)
from the top and progressively
heavier fractions at lower levels
 Bituminous Binders

• Penetration grade bitumen

• Cutback bitumen
• Bitumen Emulsions
• Modified bitumen and bitumen
emulsions
Seal Performance
 Mechanisms of failure
… pavement structure

traffic load

cracking deformation

potholes poor riding quality

 Mechanisms of failure
… surfacing (wearing course)

oxidation bleeding polishing

cracking aggregate loss

surfacing failures

potholes skid problems

 Short and long term performance
… seal types and selection

maintenance
Pavement condition

reconstruction required

Time
 When to seal
… seal types and selection
time required to programme, budget etc.

project identification
CONDITION

optimum time to reseal

at cost r x improvement due to reseal

level requiring major rehabilitation

cost of major rehabilitation R 6 - 10 x

TIME
 Factors influencing performance
… seal types and selection

• Characteristics of stone and binder

• Application rates
• Initial and long term adhesion
• Initial compaction
• Construction and traffic control
• Traffic type, volume
• Climate
• Geometry
• Existing substrate and pavement
• Seal type
• Other e.g. salts
 Aggregate Related Performance
Factors
… seal types and selection

• Average least dimension

• Flakiness index
• Shape
• Dust content
• Spread rate
• Adhesion characteristics
• Strength and abrasion resistance
 Implications ?
… application of seals and sprays

• Cheaper initial cost

• More sensitive to timeous maintenance
 Implications on maintenance
strategy?
… application of seals and sprays
• Average life of surfacing - 10 years
• Implication ?
– Resurfacing 10% of network per annum