Asphalt emulsion is a substance made up of water, asphalt binder, and an emulsifying agent.
This mixture is composed of tiny asphalt droplets suspended in water. The emulsifying agent, usually a surfactant, keeps the asphalt droplets in a stable suspension, preventing them from coalescing.
When the emulsion is applied to a surface and the water evaporates, the asphalt particles coalesce, forming a continuous asphalt layer.
Table of ContentsAsphalt Kingdom Asphalt Emulsion Sealer
Asphalt emulsion has become integral to modern construction for several reasons. These include
π Liquid Asphalt Cement
Asphalt cement is a heavy, sticky, black semi-solid, or liquid substance derived from crude oil.
It is the adhesive "glue" that, when mixed with aggregates (like stones and sand), creates the asphalt mix used for paving.
Its thick and viscous nature allows it to act as a durable binder, providing strength and flexibility to pavements.
Related: 11 Questions to Ask an Asphalt Maintenance Contractor Before You Hire One
π Water
Water acts as the carrier for the asphalt particles in an emulsion. It facilitates the distribution and application of the asphalt onto the required surfaces.
After the emulsion is applied, the water evaporates, leaving behind the asphalt to bond with the aggregate or surface.
π Emulsifying Agents
These are specialized chemicals or surfactants that allow the asphalt and water, which are naturally immiscible (they don't mix), to be stabilized in a mixed state. Think of it like how egg yolk acts in mayonnaise, preventing the oil and vinegar from separating.
Imagine you're trying to mix oil and water. On their own, they separate, with oil floating on top because they donβt naturally combine. An emulsifying agent acts as a mediator, allowing these two to coexist in a stable mixture.
In the context of asphalt emulsion, the emulsifying agents surround the tiny droplets of asphalt, creating a protective barrier that prevents these droplets from joining together and separating from the water.
These protective barriers also carry a charge, which ensures that the droplets repel each other rather than clustering together. It's similar to how magnets with the same poles repel one another.
As a result, the asphalt droplets remain finely dispersed throughout the water, forming a stable emulsion.
A colloid mill is a machine used to reduce the size of asphalt cement particles to create a stable mixture with water. Here's a step-by-step breakdown of the process.
Preparation
The basic ingredients β liquid asphalt cement, water, and emulsifying agents β are prepared. Their quantities are decided based on the desired properties of the final emulsion.
Feeding into the Colloid Mill
The asphalt cement is pumped into the mill at a high temperature to keep it in a liquid state. Simultaneously, the water mixed with the emulsifying agents is also introduced.
Size Reduction and Mixing
Inside the colloid mill, there are rotating parts and static parts with very close clearances between them. As the ingredients pass through, the asphalt is broken down into tiny droplets.
These droplets are immediately coated by the emulsifying agents and suspended in water.
Output
The resulting mixture that comes out of the colloid mill is a fine dispersion of asphalt droplets in water, which is the asphalt emulsion.
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The water used in the mixture should be clean and free from impurities. Contaminants or minerals in water can react with the emulsifying agents or asphalt, leading to unstable emulsion that can break or separate.
The pH level of the water can also influence emulsion stability. Thatβs why in many instances, distilled or deionized water is preferred.
Chemical Emulsifiers
The choice and amount of emulsifying agents are crucial. These agents determine how quickly the emulsion breaks and sets after being applied.
They also influence the stability of the emulsion during storage. Selecting the right emulsifier ensures that the asphalt droplets remain uniformly dispersed in the water and that the emulsion behaves as desired during application.
Beyond the primary components, other ingredients can be added to modify the physical properties of the emulsion:
Asphalt emulsion is classified based on the ionic charge they carry, which can significantly impact their compatibility with aggregates. These include:
These designations refer to the setting behavior and viscosity of the emulsion:
βοΈ Rapid Set (RS). This emulsion breaks rapidly and is used for quick applications like chip seals. RS emulsion resists water damage and is best for open-graded mixes.
βοΈ Medium Set (MS). With an intermediate setting rate, MS emulsion is used in mixing operations like patching mixes in shallow pavement areas.
βοΈ Slow Set (SS). This emulsion sets more slowly and ideal for fog seals, slurry seals, and tack coats. SS emulsion has time to spread and coat before breaking.
βοΈ Quick Set (QS). QS emulsion is designed to set quickly and is useful in applications similar to rapid set emulsion but can be formulated to provide a longer mixing time.
High-float emulsion has a unique property. They form a gel structure upon contact with aggregates, ensuring a thicker asphalt layer around the aggregate particles. This enhances the adhesion between the asphalt and the aggregate.
Take a look at the other benefits below.
High float emulsion is particularly beneficial in conditions where superior adhesion and water resistance are vital.
This includes areas with high rainfall, pavements with a history of stripping issues, or colder climates where freeze-thaw cycles can challenge the integrity of pavements.
When added to asphalt emulsion, polymer, and latex, they play an influential role in enhancing the overall properties of the resultant pavement.
Their introduction into the mixture brings about significant changes to the asphaltβs behavior and characteristics, making it more adaptable and resilient.
π· Strength and Elasticity. Polymers act as elastic modifiers. When added to the asphalt, they form a network structure, enhancing the binder's elasticity and memory.
This means that the pavement can deform under heavy loads and then return to its original shape once the load is removed. An increased elastic response helps the pavement resist permanent deformation, such as rutting.
π· Adhesion. Polymers, especially certain types of latex, enhance the adhesion between the asphalt binder and the aggregates.
This improved adhesion reduces the risk of stripping, where the binder might separate from the aggregates, especially in the presence of moisture. Enhanced adhesion ensures a longer-lasting pavement with fewer maintenance needs.
π· Durability. Polymers can act as antioxidants, slowing down the aging process of the asphalt binder. The oxidation process in asphalt leads to hardening and eventually, brittleness.
Polymers can delay this, ensuring the pavement remains flexible and resilient.
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Temperature fluctuations can cause several distresses in pavements, including thermal cracking and rutting. Polymers assist in mitigating these distresses:
βοΈ Resistance to Cracking. At low temperatures, traditional asphalt can become brittle and susceptible to thermal cracking due to contraction.
Polymer-modified asphalts have a lower stiffness at these temperatures, making them more flexible. This increased flexibility means that the pavement can contract and expand with temperature changes without cracking.
βοΈ Resistance to Rutting. At high temperatures, especially during peak summer, traditional asphalt pavements can become soft and start to rut under the repetitive loads of traffic.
Rutting is a surface depression in the wheel path. Polymer-modified asphalts have a higher softening point, making them more resistant to this kind of deformation.
Their elastic nature ensures they spring back to their original shape, even after being subjected to heavy loads.
Asphalt emulsion offers a distinct advantage: the ability to be modified according to specific needs. This adaptability ensures that the emulsion fits the exact requirements of the project in hand, optimizing various aspects of the pavement process.
π· Storage. By tweaking the formula, emulsion can be stabilized for longer storage periods. This means that there's a reduced need for just-in-time production, allowing flexibility in supply chain management.
π· Curing. The break or set time of an emulsion, which is when the water evaporates leaving behind the asphalt binder, can be adjusted.
For some projects, a quick set is necessary, while in other instances, a slower cure might be desired for extended working times.
π· Mixing. Asphalt emulsion can be formulated for compatibility with a range of aggregate types and sizes. This ensures that the mix quality remains consistent, with proper coating and bonding.
π· Traffic Return. Depending on the application, the emulsion can be designed to accommodate traffic sooner or later. For high-traffic areas or projects with tight timelines, quick traffic return is a huge advantage.
The ionic charge of an emulsion - positive (cationic), negative (anionic), or neutral (non-ionic) - has significant implications for its compatibility with aggregates.
βοΈ Positive (Cationic) Charges. Cationic emulsion tends to adhere better to most aggregates, which often carry a negative charge. This ensures stronger bonding and reduced stripping, making cationic emulsion popular in many applications.
βοΈ Negative (Anionic) Charges. Anionic emulsion is suitable for specific types of aggregates that have a positive charge. While less common than cationic emulsion, it serves essential functions in particular regional contexts where such aggregates prevail.
βοΈ Neutral (Non-ionic) Charges. This type of emulsion does not rely on ionic interactions to bond with aggregates. They're less common but can be useful in specialized scenarios.
The beauty of asphalt emulsion lies in its versatility. Depending on the project's specific needs, it can be modified to:
The shift towards more sustainable and environmentally-conscious construction practices has bolstered the appeal of asphalt emulsion. They present numerous advantages that are both ecologically and economically beneficial.
πΉ Minimal Hydrocarbon Emissions. Traditional hot-mix asphalt requires high temperatures for production and application.
These temperatures can result in the release of significant hydrocarbon emissions, contributing to air pollution. In contrast, asphalt emulsion is applied at much lower temperatures, dramatically reducing these emissions.
πΉ Reduced Energy Consumption. Since asphalt emulsion can be produced and applied at ambient or mildly elevated temperatures, there's a significant reduction in the energy required to heat them compared to hot-mix asphalt.
This translates to less fuel consumption, which not only reduces costs but also decreases the carbon footprint of road construction projects.
πΉ Remote Location Applications. In remote locations where setting up a hot mix plant might be challenging or not cost-effective, asphalt emulsion presents a viable alternative.
Its ambient temperature application means that roads can be constructed or maintained without the need for heavy equipment or energy-intensive processes.
πΉ Role in Recycling Systems. Asphalt emulsion plays a crucial role in cold in-place recycling (CIR) and full-depth reclamation (FDR).
In these processes, the existing asphalt pavement is milled, mixed with an emulsion, and then laid back down. This reduces the need for new aggregates and binders, conserving natural resources.
The energy and emissions associated with extracting, producing, and transporting new materials are also saved.
πΉ Water-Based Systems. Asphalt emulsion is predominantly water-based, which means it contains fewer volatile organic compounds (VOCs) than solvent-based systems. This results in a reduction of VOC emissions which can contribute to smog formation.
πΉ Reduced Resource Extraction. By maximizing the use of recycled materials in certain emulsion-based applications, there's a decreased demand for virgin aggregates and binders.
This reduces the environmental impacts associated with resource extraction.
πΉ Versatility in Repairs. Asphalt emulsion can be used for a variety of maintenance activities, including patchwork, sealcoating, and micro-surfacing.
This versatility means that road or parking lot lifespan can be extended with minor interventions, reducing the frequency of more resource-intensive overhauls.
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βοΈ Surface Treatments. Asphalt emulsion can be used as a protective layer on roads or as a sealant to fill cracks or rejuvenate older roads. These surface treatments can prolong the life of the existing pavement.
π Chip Seal. An application of asphalt emulsion followed by a layer of crushed stone or gravel. Once the stone or gravel is compacted, it provides a new wearable surface.
π Fog Seal. A light application of diluted asphalt emulsion to restore flexibility to old, oxidized pavement.
π Sand Seal. A layer of asphalt emulsion followed by a covering of sand to improve skid resistance.
βοΈ Cold Recycling. This is a method of rehabilitating an existing pavement by milling or pulverizing the old pavement and mixing it with an asphalt emulsion. The mix is then placed and compacted.
βοΈ Micro-Surfacing. A mixture of dense-graded aggregate, polymer-modified asphalt emulsion, water, and mineral fillers. It's a form of cold mix that can correct rutting and improve the road surface's skid resistance.
βοΈ Slurry Seals. A mixture of emulsified asphalt, well-graded fine aggregate, mineral filler, and water. It's a cold-mix application that restores a smooth surface to oxidized or worn-out pavements.
βοΈ Cold Mix. Used primarily for patching potholes, this mix can be stockpiled and used as needed. It's produced by mixing emulsified asphalt with cold, wet aggregates.
βοΈ Tack Coats. Used between layers of asphalt to ensure a good bond.
βοΈ Dust Control. Applying a diluted asphalt emulsion to unpaved roads to reduce dust.
βοΈ Prime Coats. Applied to untreated base materials to provide a waterproof surface and a bond between the base and the overlay.
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Asphalt emulsion is a mixture of asphalt, water, and an emulsifying agent. They're classified into three main types: anionic, cationic, and non-ionic, based on the electrical charge of the particles.
Asphalt emulsion is cost-effective, can be applied at lower temperatures, offer good binding properties, and can rejuvenate older pavements.
Yes. Asphalt Kingdom sells asphalt emulsion sealer in 55-gallon drums and skids. Buyers can also purchase asphalt emulsion sealer in a 275-gallon tote or have it delivered by bulk tanker.
Asphalt Kingdom Asphalt Emulsion Sealer | Price* |
Asphalt Emulsion Sealer (55 Gallon Drums) | $589.00 |
Asphalt Emulsion Sealer Skid (Four 55 Gallon Drums) | $1,569.00 |
4 Asphalt Emulsion Sealer Skids (16 x 55-Gallon Drums) | $5,779.00 |
Asphalt Emulsion Sealer (275 Gallon Tote) | $1,649.00 |
Asphalt Emulsion Sealer Bulk Buy (4) 275 Gallon Totes | $6,199.00 |
Asphalt Sealer: Bulk Tanker Load | Call for information |
* Prices are subject to change without prior notice
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Yes, asphalt emulsion is environmentally friendly. It contains fewer volatile organic compounds (VOCs), and its production and application consume less energy and produce fewer emissions than hot mix asphalt, contributing to sustainability.
Asphalt emulsion can be applied in various weather conditions, including colder and wetter environments, making them versatile for diverse climates.
It is used in surface treatments (like chip seals and fog seals), cold mix for patching, and cold recycling. It is also used for micro-surfacing, slurry seals, and tack coats in road construction and preservation.
Asphalt emulsion enhances safety by improving skid resistance and reducing cracking, ultimately extending the life of road surfaces.
Conclusion:
Thanks for reading this comprehensive guide on asphalt emulsion and its application in the industry. If you're ready to purchase your first drum or tote of asphalt emulsion sealer, then check out the Asphalt Kingdom store.
Whether you're a new contractor who's looking for a drum of sealer or you need an entire tanker of sealer delivered to your doorstep, we've got the right product for you.
If you need help choosing the right asphalt sealer quantity, feel free to reach out to us at 1-866-399-5562 or sales@asphaltkingdom.com.