Asphalt Cement

Background
Asphalt is a heavy, dark brown to black mineral substance, one of several mixtures of
hydrocarbons called bitumens. Asphalt is a strong, versatile weather and chemical-
resistant binding material which adapts itself to a variety of uses. Asphalt binds crushed
stone and gravel (commonly known as aggregate) into firm, tough surfaces for roads,
streets, and airport run-ways. Asphalt, also known as mineral pitch, is obtained from
either natural deposits such as native asphalt or brea or as a byproduct of the petroleum
industry (petroleum asphalt). Prehistoric animal skeletons have been preserved
completely intact in natural asphalt deposits, one of the most famous being the La Brea
Tar Pits in Los Angeles, Califomia.
Asphalt is one of the world's oldest engineering materials, having been used since the
beginning of civilization. Around 6000 B.C. the Sumerians had a thriving shipbuilding
industry that produced and used asphalt for caulking and waterproofing. As early as
2600 B.C. the Egyptians were using asphalt as a waterproofing material and also to
impregnate the wrappings of mummies as a preservative. Ancient civilizations widely
used asphalt as a mortar for building and paving blocks used in temples, irrigation
systems, reservoirs, and highways. The asphalts used by early civilizations occurred
naturally and were found in geologic strata as either soft, workable mortars or as hard,
brittle black veins of rock formations (also known as asphaltic coal). Natural asphalts
formed when crude petroleum oils worked their way up through cracks and fissures to
the earth's surface. The action of the sun and wind drove off the lighter oils and gases,
leaving a black residue. Natural asphalts were extensively used until the early 1900s.
The discovery of refining asphalt from crude petroleum and the increasing popularity of
the automobile served to greatly expand the asphalt industry. Modern petroleum asphalt
has the same durable qualities as naturally occurring asphalt, with the added advantage
of being refined to a uniform condition free from organic and mineral impurities.
Most of the petroleum asphalt produced today is used for highway surfacing. Asphalt
paving material is a dull black mixture of asphalt cement, sand, and crushed rock. After
being heated, it is dumped out steaming hot onto the roadbed, raked level, and then
compacted by a heavy steamroller. Asphalt is also used for expansion joints and
patches on concrete roads. Airport runways, tennis courts, playgrounds, and floors in
buildings all use asphalt as well. Light forms of petroleum asphalt called road oils are
sprayed on roadways to settle dust and bind gravel. Another major use of asphalt is in
asphalt shingles and roll roofing, which usually consists of felt saturated with asphalt.
The asphalt helps to preserve and waterproof the roofing material. Other applications
for asphalt include the following: waterproofing tunnels, bridges, dams and reservoirs;
rustproofing and sound-proofing metal pipes and automotive under-bodies; and
soundproofing walls and ceilings.

Raw Materials
The raw material used in modern asphalt manufacturing is petroleum, which is a
naturally

occurring liquid bitumen. Asphalt is a natural constituent of petroleum, and there are crude oils
which are almost entirely asphalt. Oil wells supply the crude petroleum to the oil refineries,
where it is separated into its various components or fractions.

The Manufacturing
Process
Crude petroleum is separated into its various fractions through a distillation process at
the oil refinery. After separation, these fractions are further refined into other products
which include asphalt, paraffin, gasoline, naphtha, lubricating oil, kerosene, and diesel
oil. Since asphalt is the base or heavy constituent of crude petroleum, it does not
evaporate or boil off during the distillation process. Asphalt is essentially the heavy
residue of the oil refining process.
Distilling the crude

 1 The refining process starts by piping the crude petroleum from a storage tank into a
heat exchanger or tube heater where its temperature is rapidly raised for initial
distillation. It then enters an atmospheric distillation tower where the lighter and more
volatile components, or fractions, vaporize and are drawn off through a series of
condensers and coolers. It is then separated for further refining into gasoline (considered
a "light" distillate), kerosene (considered a "medium" distillate), diesel oil (considered a
"heavy" distillate), and many other useful petroleum products.

The heavy residue from this atmospheric distillation process is commonly called
topped crude. This topped crude may be used for fuel oil or further processed
into other products such as asphalt. Vacuum distillation may remove enough high
boiling fractions to yield what is called a "straight run" asphalt. However, if the
topped crude contains enough low volatile components which cannot be
economically removed through distillation, solvent extraction—also known as
solvent deasphalting—may be required to produce asphalt cement of the desired
consistency.

Cutting back

 2 Asphalt may next be blended or "cut back" with a volatile substance, resulting in a
product that is soft and workable at a lower temperature than pure asphalt cement.
When the cut-back asphalt is used for paving or construction, the volatile element
evaporates when exposed to air or heat, leaving the hard asphalt cement. The relative
speed of evaporation or volatility of the cutting agent determines whether a cutback
asphalt is classified as slow, medium, or rapid-curing. Heated asphalt cement is mixed
with residual asphaltic oil from the earlier distillation process for a slow-curing asphalt,
with kerosene for medium-curing, and with gasoline or naphtha for the rapid-curing
asphalt.

Emulsifying

 3 The asphalt cement may also be emulsified to produce a liquid that can be easily
pumped through pipes, mixed with aggregate, or sprayed through nozzles. To emulsify,
the asphalt cement is ground into globules 5 to 10 microns and smaller (one micron is
equal to one millionth of a meter). This is mixed with water. An emulsifying agent is
added, which reduces the tendency of the asphalt and water to separate. The
emulsifying agent may be colloidal clay, soluble or insoluble silicates, soap, or
sulphonated vegetable oils.

Pulverizing

 4 Asphalt may also be pulverized to produce a powdered asphalt. The asphalt is

crushed and passed through a series of fine mesh sieves to ensure uniform size of the
granules. Powered asphalt can be mixed with road oil and aggregate for pavement
 construction. The heat and pressure in the road slowly amalgamates the powder with the
aggregate and binding oil, and the

substance hardens to a consistency similar to regular asphalt cement.

Air Blowing

 5 If the asphalt is to be used for a purpose other than paving, such as roofing, pipe
coating, or as an undersealant or water-proofing material, the asphalt may be oxidized,
or air blown. This process produces a material that softens at a higher temperature than
paving asphalts. It may be air blown at the refinery, at an asphalt processing plant, or at
a roofing material plant. The asphalt is heated to 500°F (260°C). Then air is bubbled
through it for one to 4.5 hours. When cooled, the asphalt remains liquid.

Asphalt Paving Mixtures

Since asphalt cement is a major constituent used in road paving, the following is a brief
 There are two types of asphalt mixes: hot-mix and cold-mix. Hot-mix asphalt (HMA) is commonly used for
heavier traffic areas while cold-mix asphalt is used for secondary roads.

description of how asphalt paving mixtures are produced. Asphalt paving mixes made with
asphalt cement are usually prepared at an asphalt mixing facility. There are two types of asphalt
mixes: hot-mix and cold-mix. Hot-mix asphalt (HMA) is more commonly used while cold-mix
asphalt (generally mixes made with emulsified or cut-back asphalts) is usually used for light to
medium traffic secondary roads, or for remote locations or maintenance use. Hot-mix asphalts
are a mixture of suitable aggregate coated with asphalt cement. The term "hot-mix" comes from
the process of heating the aggregate and asphalt before mixing to remove moisture from the
aggregate and to obtain sufficient fluidity of the asphalt cement for proper mixing and work-
ability.

 6 Asphalt cement and aggregate are combined in a mixing facility where they are
heated, proportioned, and mixed to produce the desired paving mixture. Hot-mix facilities
may be permanently located (also called "stationary" facilities), or it may be portable and
moved from job to job. Hot-mix facilities may be classified as either a batch facility or a
drum-mix facility, both can be either stationary or portable. Batch-type hot-mixing
facilities use different size fractions of hot aggregate which are drawn in proportional
amounts from storage bins to make up one batch for mixing. The combination of
aggregates is dumped into a mixing chamber called a pugmill. The asphalt, which has
also been weighed, is then thoroughly mixed with the aggregate in the pugmill. After
mixing, the material is then emptied from the pugmill into trucks, storage silos, or surge
bins. The drum-mixing process heats and blends the aggregate with asphalt all at the
same time in the drum mixer.
 7 When the mixing is complete, the hot-mix is then transported to the paving site and
spread in a partially compacted layer to a uniform, even surface with a paving machine.
While still hot, the paving mixture is further compacted by heavy rolling machines to
produce a smooth pavement surface.

Quality Control
The quality of asphalt cement is affected by the inherent properties of the petroleum
crude oil from which it was produced. Different oil fields and areas produce crude oils
with very different characteristics. The refining method also affects the quality of the
asphalt cement. For engineering and construction purposes, there are three important
factors to consider: consistency, also called the viscosity or the degree of fluidity of
asphalt at a particular temperature, purity, and safety.
The consistency or viscosity of asphalt cement varies with temperature, and asphalt is
graded based on ranges of consistency at a standard temperature. Careless
temperature and mixing control can cause more hardening damage to asphalt cement
than many years of service on a roadway. A standardized viscosity or penetration test is
commonly specified to measure paving asphalt consistency. Air-blown asphalts typically
use a softening point test.
Purity of asphalt cement can be easily tested since it is composed almost entirely of
bitumen, which is soluble in carbon disulfide. Refined asphalts are usually more than
99.5% soluble in carbon disulfide and any impurities that remain are inert. Because of
the hazardous flammable nature of carbon disulfide, trichloroethylene (TCE), which is
also an excellent solvent for asphalt cement, is used in the solubility purity tests.
Asphalt cement must be free of water or moisture as it leaves the refinery. However,
transports loading the asphalt may have moisture present in their tanks. This can cause
the asphalt to foam when it is heated above 212°F (100°C), which is a safety hazard.
Specifications usually require that asphalts not foam at temperatures up to 347°F
(175°C). Asphalt cement, if heated to a high enough temperature, will release fumes
which will flash in the presence of a spark or open flame. The temperature at which this
occurs is called the flashpoint, and is well above temperatures normally used in paving
operations. Because of the possibility of asphalt foaming and to ensure an adequate
margin of safety, the flashpoint of the asphalt is measured and controlled.
Another important engineering property of asphalt cement is its ductility, which is a
measure of a material's ability to be pulled, drawn, or deformed. In asphalt cements, the
presence or absence of ductility is usually more important than the actual degree of
ductility because some asphalt cements with a high degree of ductility are also more
temperature sensitive. Ductility is measured by an "extension" test, whereby a standard
asphalt cement briquette molded under standard conditions and dimensions is pulled at
a standard temperature (normally 77°F [25°C]) until it breaks under tension. The
elongation at which the asphalt cement sample breaks is a measure of the ductility of
the sample.

Byproducts/Waste
Environmental protection laws have developed stringent codes limiting water flows and
particulate and smoke emissions from oil refineries and asphalt processing plants. Not
only dust but sulfur dioxides, smoke, and many other emissions must be rigorously
controlled. Electrostatic precipitators, primary dust collectors using single or multiple
cone cyclones, and secondary collection units consisting of fabric filter collectors
commonly called "baghouses" are all required equipment to control emissions.
Hydrocarbons formed in asphalt production, if unchecked, create odoriferous fumes and
pollutants which will stain and darken the air. Pollutants emitted from asphalt production
are controlled by enclosures which capture the exhaust and then recirculate it through
the heating process. This not only eliminates the pollution but also increases the heating
efficiency of the process.
Higher costs of asphalt cement, stone, and sand have forced the industry to increase
efficiencies and recycle old asphalt pavements. In asphalt pavement recycling,
materials reclaimed from old pavements are reprocessed along with new materials. The
three major categories of asphalt recycling are 1) hot-mix recycling, where reclaimed
materials are combined with new materials in a central plant to produce hot-mix paving
mixtures, 2) cold-mix recycling, where reclaimed materials are combined with new
materials either onsite or at a central plant to produce cold-mix base materials, and 3)
surface recycling, a process in which the old asphalt surface pavement is heated in
place, scraped down or "scarified," remixed, relaid, and rolled. Organic asphalt recycling
agents may also be added to help restore the aged asphalt to desired specifications.
Because of solvent evaporation and volatility, use of cutback asphalts, especially
rapidcure cutback asphalts which use gasoline or naphtha, is becoming more restricted
or prohibited while emulsified asphalts (in which only the water evaporates) are
becoming more popular because of cost and environmental regulations.

The Future
Increasing economic and environmental needs will bring many new technical
frefinements to recycling old asphalt pavements, such as using microwaves to
completely break down the pavement. Microwaves heat the crushed rock in asphalt
pavement faster than the surrounding cement, which is then warmed by the radiant heat
from the rock. This method prevents the asphalt cement from burning.
Alternative sources of raw material are being researched, such as the production of
synthetic asphalt from the liquefaction of sewage sludge. To ensure consistent product
quality, new methods are being developed for manufacturing modified asphalts and
emulsions. Many new tests are being developed to help characterize asphalts, such as
high-performance gel-permeation chromatography (HP-GPC), which allows many
properties to be studied and the results compiled in only a few minutes. New processes,
more efficient mixing and milling units, in-line liquid mass flow meters, on-line
monitoring systems, and new safety equipment are some other areas being investigated
for improvement.
Polymer-modified asphalt crack sealers are gaining in popularity, and many other
asphalt modifiers are being developed. Modifiers are added to control pavement rutting,
cracking, asphalt oxidation, and water damage. Some commercially available asphalt
modifiers are polymers, including elastomers, metal complexes, elemental sulfur, fibers,
hydrated lime, Portland cement, silicones, various fillers, and organic anti-strip agents.
Many of these modifiers have not been extensively used and are being researched for
further development. It might even be possible one day to have "smart asphalt cements"
by mixing in certain asphalt friction modifiers which would allow it to change
characteristics depending on whether moisture was present. In conjunction
with antilock brakes, automatic traction controls, and airbags, this could serve to save
many lives on our nation's highways.
Read more: http://www.madehow.com/Volume-2/Asphalt-Cement.html#ixzz7PFe0VYin

Asphalt pavements are widely used for roads, parking lots, industrial surfaces,
recreational surfaces, and walking trails. Asphalt pavements are made by combining
rocks and sand to a particular recipe and then adding asphalt cement as the black
sticky glue that holds the pavement together.
 
The combination of rocks and sand is very important to the structure and strength of the
pavement. The recipe needs to allow for the pavement to be densely compacted and
provide enough strength to resist heavy traffic loads.
 
Asphalt cement is a dark heavy mixture of hydrocarbons, also called bitumen, that is
extracted as a byproduct of gasoline production (crude oil distillation). Asphalt cement is
a durable material resistant to harsh chemicals and extreme weather. Different grades
of asphalt cement are used to increase the performance of asphalt pavements, so be
sure to ask Bituminous Roadways about your options
 
Asphalt cement is solid (or very, very viscous) at room temperature, but when heated,
asphalt turns to a liquid. Therefore, the rocks and sand and asphalt cement have to be
heated to about 300°F before being mixed together in a large rotating drum mixer. The
asphalt pavement mixture is quickly transported to the project location and is placed at
the proper thickness and slope using an asphalt paver before it has time to cool. Lastly,
as the pavement cools, several compaction rollers are used to densify the asphalt
pavement.  
 
Asphalt pavements are ideal for paving roads, parking lots, airport runways, walking
trails, tennis courts or any other small or large-scale projects where a smooth flat
surface is required.
 
What are the benefits of asphalt pavements?
 
Safe. Asphalt surfaces are perfect for driving on because they provide a safe, smooth,
and quiet surface for vehicles traveling at higher speeds. Asphalt can also reduce
splashing and spraying from tires during precipitation, reducing collisions on the
highway.
 
Low-cost. When compared to other types of hard surfaces, asphalt is far more cost
effective. It lasts longer and requires less maintenance. Smoother roads also reduce the
wear and tear on vehicles. Therefore, they save vehicle owners money on maintenance.
 
Eco-friendly. Asphalt is a recyclable product. In the United States, the asphalt industry
recycles almost 100 million tons of asphalt pavement annually for reuse in other areas.
This saves taxpayers nearly $2 billion per year in road costs.
 
Durability. Asphalt pavements can be designed for low, medium or high-volume traffic.
With routine maintenance, asphalt can last 15-20 years.
 
Flexibility. Asphalt can be used for a wide range of projects. In addition to roads,
parking lots, and trails, it's also used for roofing material, ramps, bicycle paths, and even
on bridges.
 
Bituminous Roadways, Inc. can help you with your next project
When deciding to launch your project, Bituminous Roadways can help you every step of
the way from layout design to finishing and detailing the asphalt surface. With more than
700 years of combined field experience, we have the training and skill necessary to
perform all jobs, large and small.
 
If you are looking for asphalt installation, repair, or surface replacement,
contact Bituminous Roadways. We provide a wide range of services and products for
industrial and commercial business owners in the Twin Cities Metro area. Call us today
at 651-686-7001 for a free estimate and consultation.
 

Cutback Asphalt
A cutback asphalt is simply a combination of asphalt cement and petroleum
solvent. Like emulsions, cutbacks are used because they reduce asphalt viscosity
for lower temperature uses (tack coats, fog seals, slurry seals, stabilization
material). Similar to emulsified asphalts, after a cutback asphalt is applied the
petroleum solvent evaporates leaving behind asphalt cement residue on the
surface to which it was applied. A cutback asphalt is said to “cure” as the petroleum
solvent evaporates away. The use of cutback asphalts is decreasing because of
(Roberts et al., 1996[1]):

 Environmental regulations. Cutback asphalts contain volatile chemicals that

evaporate into the atmosphere. Emulsified asphalts evaporate water into the
atmosphere.
 Loss of high energy products. The petroleum solvents used require higher
amounts of energy to manufacture and are expensive compared to the water and
emulsifying agents used in emulsified asphalts.
In many places, cutback asphalt use is restricted to patching materials for use in
cold weather.

Cutback asphalt, emulsified asphalt products and

volatile organic compounds
In Canada, there are more than one million kilometres of roads
and highways, almost half of which are paved with asphalt. There
is also a large number of parking lots and private driveways that
are paved.
Cutback asphalt and emulsified asphalt are liquefied asphalt
products that are commonly used in road construction. Cutback
asphalt is prepared by mixing asphalt cement with a petroleum
solvent, while emulsified asphalt is prepared by mixing asphalt
cement with emulsifiers, water, and sometimes a small amount of
petroleum solvent. The petroleum solvent contains a high
concentration of volatile organic compounds which evaporate
once the liquefied asphalt cement is applied during road
construction, leaving behind the cured residual asphalt cement.

ASPHALT CUTBACKS
Solvents of lower volatility evaporate more slowly.
Asphalt cutbacks use petroleum solvents for dissolving asphalt cement. The
solvents are variously called distillate, diluents, or cutter stock. If the solvent
used in making the cutback asphalt is highly volatile, it will quickly escape by
evaporation. Solvents of lower volatility evaporate more slowly. On the basis of
the relative speed of evaporation, cutback asphalts are divided into three
types: rapid curing (RC), medium curing (MC) and slow curing (SC).

Rapid Curing Cutbacks

Rapid curing asphalt cement is a combination of light diluents of high

volatility, generally in the gasoline or naphtha boiling point range (RC-70,
250, 800, 3000), and asphalt cement.
Medium Curing Cutbacks

Medium curing asphalt cement uses medium diluents of intermediate

volatility generally in the kerosene boiling point range (MC-30, 70, 250, 800,
3000).

Slow Curing Cutbacks

Slow curing asphalt cement and oils of low volatility generally in the heavy
distillate range (SC-70, 250, 800, 3000).

Proprietary/Branded Cutbacks

McAsphalt’s expertise in cutback production and modification, and our state-

of-the-art facilities, allow us to custom blend cutback products for road and
related industries.

An Introduction to Asphalt Emulsions

Asphalt emulsions are an environmentally friendly, energy efficient and cost
effective product for use in today’s paving and preservation efforts. But,
what are they and how are they made?

What Is an Asphalt Emulsion?

An asphalt emulsion is liquid asphalt cement emulsified in water. It is composed of asphalt,
water and an emulsifying agent. The emulsifying agent is sometimes called the surfactant,
which is composed of large molecules. These soap molecules are like tadpoles, having a
hydrocarbon tail soluble in liquid asphalt and an electrically charged or ionic head soluble in
water. The asphalt particles are surrounded by the ionic charge, which causes the droplets
to repel each other and stay suspended in the water.

All asphalt emulsions are designed to eventually break, or revert to asphalt and water.
Some emulsions break by chemically destabilizing the surfactant, others by a simple
evaporation of the water. Still others break by a combination of chemical destabilization and
evaporation.

Today’s emulsion manufacturers have many new chemistries available to design the
emulsion for the optimal break time and specific use.

How Are Emulsions Made?

Asphalt cement is the basic ingredient of asphalt emulsions. In most cases, it makes up
from 50 to 75 percent of the emulsion. Some properties of the asphalt significantly affect
the finished emulsion. But there is not an exact correlation between the properties and the
ability to emulsify the asphalt. The properties of the asphalt cement do affect the
performance of the residual asphalt on the road.
Water is the second ingredient in an asphalt emulsion. Minerals or other materials in water
can affect the production of stable emulsions. Water that is suitable for drinking may not be
suitable for asphalt emulsions.

The chemical used as an emulsifier greatly influences the properties of an asphalt emulsion.
The emulsifier keeps the asphalt particles in suspension and controls the breaking time. It
also determines whether the emulsion is cationic or anionic (or non-ionic). Chemical
compatibility of the emulsifying agent with the asphalt cement is essential for producing a
stable emulsion.

The emulsion is produced by separately metering the soap and water solution and hot liquid
asphalt into a colloid mill at predetermined rates and temperatures. The colloid mill shears
the asphalt into microscopic particles. The size of the particles affects the physical
properties of the emulsion.

Sometimes additional ingredients, including latex, polymers, acids and other additives are
fed into the emulsion to further modify its physical characteristics.

BASICS OF ASPHALT
EMULSIONS
What is an asphalt emulsion?
Asphalt emulsion is a combination of three
basic ingredients, asphalt, water, and small
amount of an emulsifying agent. In the
same process, these components are
introduced into a mechanism known as a
colloid mill, which shears the asphalt into
tiny droplets. The emulsifier, which is a
surface-active agent, keeps the asphalt
droplets in a stable suspension and controls
the breaking time. The result is a liquid
product with a consistency ranging from that
of milk to heavy cream, which can be used
in cold processes for road construction and
maintenance.

Why use asphalt emulsions?

Asphalt emulsion does not require a
petroleum solvent to make it liquid and in
most cases asphalt emulsions can be used
without additional heat. Both of these
factors contribute to energy savings.
Additionally, asphalt emulsions offer great
flexibility in their application since they offer
the end-user a great variety of
characteristics not found in other paving
and maintenance materials. Asphalt
emulsions are environmentally friendly.
There are little or no hydrocarbon emissions
created with their use.

Are asphalt emulsions new?

Asphalt emulsions were first prepared in the
early part of the 20th century and today they
are used all over the world. The use of
asphalt emulsions is growing and 10-20% of
all asphalt is used in the form of asphalt
emulsions.

How are asphalt emulsions

classified?
Asphalt emulsions are classified into three
categories; anionic, cationic, or nonionic.
The anionic and cationic classes refer to the
electrical charges surrounding the asphalt
particles. The absence of the letter “C”
denotes anionic emulsions. Asphalt
emulsions are further classified on the basis
of how quickly they coalesce; i.e., revert to
asphalt cement. The terms RS (Rapid Set),
MS (Medium Set), SS (slow set), and QS
(Quick Set) have been adopted to simplify
and standardize this classification.
Additionally, trailing numbers are used to
delineate the relative viscosity if the
emulsion and the letters “h” and “s” indicate
whether a hard or soft base asphalt is used
to make the asphalt emulsions. Thus, a
CSS-1h is a cationic slow set emulsion with
a relatively low asphalt emulsion viscosity
made with a hard base asphalt.

Do asphalt emulsions have any

uses around the home?
Driveway sealers, roofing repair materials,
caulks and mastics may contain specially
formulated asphalt emulsions.