AUSTROADS PAVEMENT RESEARCH GROUP

Transport Research

February 1999

APRG TECHNICAL NOTE 8

ULTRA THIN ASPHALT SURFACING1

restore the surface characteristics of otherwise sound pavements. A number of systems were developed, some of which have proprietary names. Generally, the surfacings are a variation of coarse gap-graded mixes, somewhat similar to stone mastic asphalt but with a lower binder and filler content. Generally the mixes are permeable but contain more fine aggregate than standard open-graded surfacing to provide greater mechanical stability and resistance to shearing forces. An early development of UTA in France was the use of a purpose-built machine that combined the spraying of binder and spreading of asphalt surfacing material in one operation. In this regard the heavy tack coat was considered to hold the bottom layer of asphalt aggregate in place in a manner similar to a sprayed seal. Initial trials with the French built machine were carried out in Australia in 1993 (Ref. 1). A similar combination of tack coat application and asphalt spreading is achieved with conventional asphalt pavers that have been extended to incorporate a tack coat spray bar ahead of the asphalt distribution augers. Such machines have been purchased by the major asphalt companies in Australia. These enable tack coats to be applied at high rates without being damaged by spreading vehicles.

Typical ultra thin surfacing

Introduction
Ultra thin asphalt (UTA) surfacings are typically placed with a minimum thickness of around 12-15 mm, or about half the thickness of similar sized conventional asphalt wearing course mixes. The main characteristics of UTA surfacings are the use of a heavy tack coat or sprayed seal to form an integral bond with the underlying surface, and the adoption of coarse gap-graded mixes to provide good surface texture. The achievement of a strong bond distinguishes UTA from conventional asphalt surfacings that achieve a level of independent integrity in each layer. The tack coat, or seal, used to bond the surfacing in place also assists in waterproofing the pavement where permeable surfacing materials are used. Coarse gap-graded mixes can achieve an open texture similar in appearance to open-graded asphalt, thus providing good noise, skid resistance, and water spray characteristics. Over time, however, there may be some reduction in texture. Achievement of a uniform thin layer of paver- laid asphalt can only be achieved where the underlying surface is in good shape. Where necessary, shape correction should be carried out before placing UTA.

Process
The most common UTA process involves the spraying of up to 0.9 L/m2of an emulsion tack coat on the surface immediately ahead of the spreading of the asphalt layer. High tack coat application rates require the use of specially-modified asphalt pavers as referred to above. UTA is compacted with steel-wheel rollers using similar techniques to those used for conventional open-graded or stone mastic asphalt mixes. Handwork should be kept to a minimum.

Background

Ultra thin surfacing techniques were developed in Europe, driven by the desire for thin economical treatments to 1 (Supersedes Ultra thin asphalt surfacings NOVACHIP, May 1994)

Materials and Design

Bitumen emulsion tack coats must be appropriate to the UTA application. Generally a polymer modified, 62% binder content emulsion is used to provide the rate of cure and development of bond required. Such emulsions are applied at a temperature of 6080C. The heat of the asphalt mix completes the breaking of the bitumen emulsion tack coat. The design criteria for UTA mixes are not well defined. Most of the work done to date has been with 10 mm nominal size mixes meeting the gradings limits shown in Table 1. Smaller nominal sizes of similar grading type have also been used. For heavily-trafficked applications, polymer modified binders are used to provide a higher level of binder cohesion and durability, as well as reducing the risk of binder drainage during transport. Properties of UTA mixes can be determined using the procedures contained in the Australian Provisional Guide to the Selection and Design of Asphalt Mixes (Ref. 2). Table 1 Typical Combined Grading for UTA AS Sieve Size (mm) Percentage (by mass) Range 13.2 9.5 6.7 4.75 2.36 1.18 0.60 0.30 0.15 0.075 Binder content 100 80100 3055 2040 1836 1430 1025 720 612 48 4.75.4 Passing Typical Target 100 90 40 30 27 22 18 13 9 6 5.0

SAMI treatment is used. Where shape correction is necessary, it is done prior to the application of the SAMI. When combined with SAMI treatments, waterproofing and bonding to the underlying surface is provided by the sprayed seal binder, while the thin surfacing forms an integral bond with the sprayed seal. In such cases, tack coat emulsion application rates may be reduced to 0.5 L/m2 or even omitted entirely. Caution must be used in applying surfacing to fresh seals/patches or flushed surfaces to avoid flushing of the UTA. Fine aggregate in the UTA mix provides greater resistance to surface shear stresses than a standard open-graded but the thin layer can be susceptible to damage where tight turning movements of heavy vehicles occur. The service life has not been determined in Australian conditions but it is anticipated to be comparable to other permeable asphalt types and dependant on binder type and service conditions.

Advantages
Economical cost moderately less than that of conventional asphalt surfacing. High standard of surface texture giving good skid resistance and reduced water spray. Reduced noise levels compared to dense-graded asphalt and sprayed seals. Good ride qualities. Flexible and tolerant to surface deflections. Assists waterproofing of underlying surface. Thin layer reduces need for cold planing, etc. to match adjoining surfaces. No loose aggregate such as in a spray seal.

Disadvantages
Higher cost than sprayed seal. Effective treatment may require regulation and SAMI treatments. preliminary

Applications and Experience of Performance

In Australia, UTA surfacing has been used for resurfacing asphalt, sprayed seal and concrete pavements. In some instances, UTA has been used in conjunction with a sprayed seal as a Strain Alleviating Membrane Interlayer (SAMI). UTA provides a smooth, quiet surface with greater resistance to surface stresses than a sprayed seal on its own, as well as eliminating loose aggregate associated with sprayed seals. On cracked pavements a geotextile

Low shear resistance may make it unsuitable in areas of high shear forces.

References
1. 2. APRG (1994). Ultra thin asphalt surfacings NOVACHIP. Technical Note 3. Austroads, Sydney. APRG (1997). Selection and Design of Asphalt Mixes: Australian Provisional Guide. Report No 18. Austroads, Sydney.

For further information please contact

John Bethune, AAPA Tel (03) 9853 3595, Fax (03) 9853 3484 Ian Cossens, GeoPave, VicRoads Tel (03) 9881 8915, Fax (03) 9881 8900