Guidelines for the preparation of

High Performance Cold Patch Mix

General Requirements

The patching material shall be a plant mix composed of a suitable aggregate, a liquid asphalt (such as
cutback) and a chemical additives such as Kling Beta LL. The liquid asphalt shall meet the requirements as
listed below in Item No. 2. The bituminous material shall be capable of coating approved wet aggregates
without stripping, and shall be available in various grades so that one such grade will enable a stockpile to
remain pliable and workable at a temperature below -10°C. The patching material shall be capable of
maintaining adhesive qualities in areas, which are damp or wet at time of application, and it shall not bleed or
flush when overlaid with hot mix. Open graded mixes of this material shall be capable of maintaining all of its
performance features after remaining in an uncovered stockpile of 100 tons or more, for up to 12 months.

Materials

1. Aggregates: Shall be crushed limestone or other approved material of equal hardness. The aggregate
shall meet the following gradations:

Open Graded # 9 Open Graded #89 Dense Graded*

Sieve Size % Passing % Passing % Passing
3/8 inch 100 90 – 100 90 – 100
No. 4 85 – 100 20 – 55 55 – 85
No. 8 10 – 40 5 – 30 32 – 67
No. 16 0 – 10 0 – 10 18 – 48
No. 30 0–7 0–7 10 – 33
No. 50 0–5 0–5 5 – 15
- 200 Sieve (wash) 0 – 2.5 0 – 2.5 2–6

*This gradation is designed for use when the air temperature has been 7°C or higher for a minimum of 48
hours.

2. Bituminous Material: The liquid asphalt/cutback can be prepared from base asphalts such as 85-100
pen, 120-150 pen, AC-10, AC-20, AR-2000, or AR-4000. The cutback should be prepared in accordance
with the recommended blending formula provided by the asphalt manufacturer. A typical dosage of about
2 to 3% Klilng Beta LL is blended with the cutback. For certain difficult aggregates an additional 0.3 to
0.5% Duomeen O or Wetfix 312 could be needed in order to fulfill the requirements of the ASTM D-
1664/AASHTO T-182 test. The cutback thus prepared shall meet the following requirements:

1
 Flash Point (TOC): 200°F Minimum
Kinematic Viscosity @ 140°F: 300 – 4000
Water: 0.2% Maximum
Distillate Test (Volume of original sample):
To 437°F: None
To 500°F: 0 – 5%
To 600°F: 0 – 25%
Residue from Distillate @ 680°F: 72 – 95%
Residue Tests:
Absolute Viscosity @ 140°F: 125 – 425 poises
Penetration @ 140°F, cone
Method, 150  1 gm total load: 180 Minimum
Ductility @ 38°F, 1 cm/min: 100 Minimum
Solubility in Trichloroethylene: 99% Minimum

Composition of the patch mix

The mix shall consist of an aggregate conforming to Item No. 1, and a bituminous material conforming to
Item No. 2 mixed in such a manner as to contain about 60 Kilograms of bituminous material per ton of patch
mix (6.00%). The asphalt content of the patch mix should be within the recommended range listed below.

Minimum Maximum

Job Mix Formula 5.5% 7.0%

(55Kgs/ton) (70 Kgs/ton)

By Extraction 3.5% 7.0%

Preparation of the patch mix

The bituminous material shall be heated to a temperature of between 65 and 120°C and blended with the
approved aggregate, which has been surfaced dried. The temperature while mixing shall not exceed 80°C.
Mixing shall continue until all aggregates are uniformly coated.

Storage and mixing equipment

Storage facilities and all equipment used in the preparation of the mixture shall be approved by the
appropriate local governing agency. An approved drier shall be available for surface drying the aggregate
when needed. The materials for individual batches shall be measured accurately either by volume or by
weight, by approved methods and equipment.
A batch type mixer of approved design and capacity shall be used in mixing the ingredient materials.
However, approval for the use of a continuous mixer or portable pug mill, may be given if it can show that
satisfactory results will be obtained.

Stripping test for the patch mix

Immediately after mixing, the patching material shall be tested according to ASTM D-1664 or AASHTO
T-182 and shall retain at least a 95% coated surface.

2
Stockpile Procedures

Following production, the patching material should be allowed to cool to ambient temperatures prior to
use. This is achieved by storing the mix in stockpiles not higher than 6 feet for about 24 to 48 hours. Once the
patch mix has reached ambient temperatures, open graded mixes can be mounded into a single normal height
stockpile. Dense graded mixes should be continually stored in stockpiles not higher than 6 feet.

Open graded mixes may be stored in an uncovered stockpile of 100 tons or more, for up to one year.
However, in severely cold environments it may be necessary to either cover open graded stockpiles, or should
be allowed to store indoors at a minimum temperature of 10°C for about 12 hours prior to application. This is
to eliminate the presence of any ice crystals in the patch mix.

Dense graded mixes may be stored in an uncovered stockpile of 100 tons or more, for up to six months if
the air temperature remains above 7°C.

Handling precautions

During the production of the cold patching mix, and during the production or handling of cutback asphalt,
necessary safety precautions should be taken to prevent any possible fire hazard. Precautions to prevent
cigarette smoking and any other form of ignition or combustion should be strictly enforced in the general
vicinity of such operations. In addition care should be taken to follow the recommended storage temperature
for the asphalt, cutback asphalt and any solvent that are used.