Crack resistant layer with good beam fatigue properties made from an emulsion of a polymer modified bituminous binder and method of selecting same

Abstract

A method of selecting a crack resistant layer to be applied to an existing surface, the method comprising the steps of: selecting at least one emulsified bituminous binder to examine, where the emulsified bituminous binder comprises bitumen, one or more emulsifier, and one or more polymers, where the one or more polymers, the one or more emulsifier, or both include a sufficient amount of conjugated diene such that at least 2.5% of the weight of the emulsified bituminous binder residuum comprises conjugated diene, preferably at least 3.0%, more preferably at least 3.5%, and most preferably 4.0%; forming at least one bituminous mixture comprising the emulsified bituminous binder and an aggregate; testing each bituminous mixture for fatigue properties; and selecting a bituminous binder for use in the crack resistant layer. The method may further comprise the steps of testing the bituminous mixture for fracture energy and selecting the emulsified bituminous binder for use in the crack resistant layer based on fatigue properties and fracture energy properties, and/or testing the emulsified bituminous binder residuum for fracture energy and selecting the emulsified bituminous binder for use in the crack resistant layer based on fatigue properties and bituminous binder residuum fracture energy properties.

1 . A method of selecting a crack resistant layer to be applied to an existing surface, the method comprising the steps of:
 selecting at least one emulsified, bituminous binder to examine, where the emulsified bituminous binder comprises bitumen, one or more emulsifier, and one or more polymers, where the one or more polymers, the one or more emulsifier, or both include a sufficient amount of conjugated diene such that at least 2.5% of the weight of emulsified bituminous binder residuum comprises conjugated diene;   forming at least one bituminous mixture comprising the emulsified bituminous binder and an aggregate;   testing each bituminous mixture for fatigue properties; and   selecting a bituminous binder for use in the crack resistant layer.   
     
     
         2 . The method of  claim 1  where at least 3.0% of the weight of the emulsified bituminous binder residuum comprises conjugated diene. 
     
     
         3 . The method of  claim 1  where at least 3.5% of the weight of the emulsified bituminous binder residuum comprises conjugated diene. 
     
     
         4 . The method of  claim 1  where at least 4.0% of the weight of the emulsified bituminous binder comprises residuum conjugated diene. 
     
     
         5 . The method of  claim 1  where at least part of the conjugated diene included in the emulsified bituminous binder comes from latex. 
     
     
         6 . The method of  claim 5  where the emulsified bituminous binder is formed by emulsifying a bituminous binder, and where the latex is added to the bituminous binder before emulsification, during emulsification, after emulsification, or combinations thereof. 
     
     
         7 . The method of  claim 1  where selecting the emulsified bituminous binder for use in the crack resistant layer is based on mixture fatigue properties. 
     
     
         8 . The method of  claim 7  where the testing of each bituminous mixture for fatigue properties comprises subjecting each bituminous mixture to a flexural beam fatigue test performed at 2,000 microstrains, 10 Hz, and 15° C. per ASTM D 7460-08. 
     
     
         9 . The method of  claim 8  the flexural beam fatigue test results in at least 5,000 cycles to failure. 
     
     
         10 . The method of  claim 8  the flexural beam fatigue test results in at least 10,000 cycles to failure. 
     
     
         11 . The method of  claim 8  the flexural beam fatigue test results in at least 15,000 cycles to failure. 
     
     
         12 . The method of  claim 1  further comprising the steps of testing the emulsified bituminous mixture for fracture energy and selecting the emulsified bituminous binder for use in the crack resistant layer based on fatigue properties and fracture energy properties. 
     
     
         13 . The method of  claim 12  where the testing of the emulsified bituminous mixture for fracture energy comprises subjecting the emulsified bituminous mixture to a Semi-Circular Bend Test or a Disk-Shaped Compact Tension Test. 
     
     
         14 . The method of  claim 13  where the fracture energy test is the Disk-Shaped Compact Tension Test and is performed at a temperature of −10° C. and a rate of loading of 1.0 mm/min, in accordance with ASTM D 7313-07. 
     
     
         15 . The method of  claim 14  where the fracture energy test results in a mixture fracture energy of greater than 600 J/m 2 . 
     
     
         16 . The method of  claim 14  where the fracture energy test results in a mixture fracture energy of greater than 700 J/m 2 . 
     
     
         17 . The method of  claim 14  where the fracture energy test results in a mixture fracture energy of greater than 800 J/m 2 . 
     
     
         18 . The method of  claim 1  further comprising the steps of testing the emulsified bituminous binder residuum for fracture energy and selecting the emulsified bituminous binder for use in the crack resistant layer based on fatigue properties and bituminous binder residuum fracture energy properties. 
     
     
         19 . The method of  claim 18  where the testing of the bituminous binder residuum for fracture energy comprises testing a single edge notch beam tested at 0.1 mm/sec at −30° C., calculated by ASTM D 5045-99 where the dimensions of the single edge notched beam are B=6.0 mm, W=9.5 mm, A=4.9 mm, and L=44.0 mm where the samples were conditioned at test temperature for 18 to 20 hours before testing. 
     
     
         20 . The method of  claim 19  where the fracture energy test results in a bituminous binder residuum fracture energy of greater than 40 J/m 2  where the samples were conditioned at test temperature for 18 to 20 hours before testing. 
     
     
         21 . The method of  claim 19  where die fracture energy test results in a bituminous binder residuum fracture energy of greater than 50 J/m 2  where the samples were conditioned at test temperature for 18 to 20 hours before testing. 
     
     
         22 . The method of  claim 19  where the fracture energy test results in a bituminous binder residuum fracture energy of greater than 60 J/m 2  where the samples were conditioned at test temperature for 18 to 20 hours before testing. 
     
     
         23 . The method of  claim 12  further comprising the steps of testing the bituminous binder residuum for fracture energy and selecting the emulsified bituminous binder for use in the crack resistant layer based on fatigue properties, mixture fracture energy properties, and bituminous binder fracture energy properties. 
     
     
         24 . The method of  claim 1  further comprising the steps of testing the bituminous mixture for permeability and selecting the emulsified bituminous binder for use in the crack resistant layer based on fatigue properties and permeability. 
     
     
         25 . The method of  claim 24  where the bituminous mixture is tested for permeability in accordance with ASTM D 3637. 
     
     
         26 . The method of  claim 25  where the permeability is greater than 8 cm 2 . 
     
     
         27 . The method of  claim 1  where the bituminous mixture has a Hveem stability of greater than 21 per ASTM D 1560. 
     
     
         28 . The method of  claim 1  where the bituminous mixture has greater than 1% air voids. 
     
     
         29 . The method of  claim 1  where the emulsified bituminous binder further comprises additives. 
     
     
         30 . The method of  claim 29  where the additives comprise cross-linking agents, accelerators, extenders, fluxing agents, or combinations thereof. 
     
     
         31 . The method of  claim 1  where the aggregate comprises a hard and inflexible mineral aggregate, a hard and inflexible man-made aggregate, or a combination thereof. 
     
     
         32 . The method of  claim 1  where the bituminous mixture further comprises recycled materials. 
     
     
         33 . The method of  claim 32  where the recycled materials are reclaimed asphalt pavement, glass, ground rubber tires, ceramics, metals, or mixtures thereof. 
     
     
         34 . A crack resistant layer to be applied to an existing surface, where the layer comprises:
 an aggregate; and   an emulsified bituminous binder, wherein the bituminous binder is comprised of bitumen and one or more polymers, where the one or more polymers include a sufficient amount of conjugated diene such that at least 2.5% of the weight of emulsified bituminous binder residuum comprises conjugated diene, and where the bituminous binder is emulsified to form an emulsified bituminous binder;   where the emulsified bituminous binder and the aggregate are mixed and form a bituminous mixture wherein the mixture has a flexural beam fatigue resistance of at least 5,000cycles at 2000 microstrains at 10 Hz when tested 15° C. per ASTM D 7460-08.   
     
     
         35 . The crack resistant layer of  claim 34  where at least 3.0% of the weight of the emulsified bituminous binder residuum comprises conjugated diene. 
     
     
         36 . The crack resistant layer of  claim 34  where at least 3.5% of the weight of the emulsified bituminous binder residuum comprises conjugated diene. 
     
     
         37 . The crack resistant layer of  claim 34  where at least 4.0% of the weight of the emulsified bituminous binder residuum comprises conjugated diene. 
     
     
         38 . The crack resistant layer of  claim 34  where at least part of the conjugated diene comprising the bituminous binder residuum comes from latex. 
     
     
         39 . The method of  claim 38  where the latex is added to the bituminous binder before emulsification, during emulsification, after emulsification, or combinations thereof. 
     
     
         40 . The crack resistant layer of  claim 34  where the layer exhibits beam fatigue properties of at least 10,000 cycles to failure when subjected to a flexural beam fatigue test at 2000 microstrains at 10 Hz when tested 15° C. per ASTM D 7460-08. 
     
     
         41 . The crack resistant layer of  claim 34  where die layer exhibits beam fatigue properties of at least 15,000 cycles to failure when subjected to a flexural beam fatigue test at 2000 microstrain at 10 Hz when tested 15° C. per ASTM D 7460-08. 
     
     
         42 . The crack resistant layer of  claim 34  where the bituminous mixture exhibits desirable fracture energy properties when subjected to testing for such fracture energy properties. 
     
     
         43 . The crack resistant layer of  claim 42  where the bituminous mixture is tested for fracture energy properties with a Semi-Circular Bend Test or a Disk-Shaped Compact Tension Test. 
     
     
         44 . The crack resistant layer of  claim 43  where the fracture energy test is performed at a temperature of −10° C. and a rate of loading of 1.0 mm/min., in accordance with ASTM D 7313-07. 
     
     
         45 . The crack resistant layer of  claim 44  where the bituminous mixture's fracture energy properties are desirable if the fracture energy test results in a mixture fracture energy of greater than 600 J/m 2 . 
     
     
         46 . The crack resistant layer of  claim 44  where the bituminous mixture's fracture energy properties are desirable if the fracture energy test results in a mixture fracture energy of greater than 700 J/m 2 . 
     
     
         47 . The crack resistant layer of  claim 44  where the bituminous mixture's fracture energy properties are desirable if the fracture energy test results in a mixture fracture energy of greater than 800 J/m 2 . 
     
     
         48 . The crack resistant layer of  claim 34  where the emulsified bituminous binder residuum has a fracture energy of greater than 40 J/m 2  when a single edge notch beam is tested at 0.1 mm/sec. at −30° C., calculated by ASTM D 5045-99 where the dimensions of the single edge notched beam are B=6.0 mm, W=9.5 mm, A=4.9 mm, and L=44.0 mm where the samples were conditioned at test temperature for 18 to 20 hours before testing. 
     
     
         49 . The crack resistant layer of  claim 34  where the emulsified bituminous binder residuum has a fracture energy of greater than 50 J/m 2  when a single edge notch beam is tested at 0.1 mm/sec. at −30° C., calculated by ASTM D 5045-99 where the preferred dimensions of the single edge notched beam are B=6.0 mm, W=9.5 mm, A=4.9 mm, and L=44.0 mm where the samples were conditioned at test temperature for 18 to 20 hours before testing. 
     
     
         50 . The crack resistant layer of  claim 34  where the emulsified bituminous binder residuum has a fracture energy of greater than 60 J/m 2  when a single edge notch beam is tested at 0.1 mm/sec. at −30° C., calculated by ASTM D 5045-99 where the preferred dimensions of the single edge notched beam are B=6.0 mm, W=9.5 mm, A=4.9 mm, and L=44.0 mm where the samples were conditioned at test temperature for 18 to 20 hours before testing. 
     
     
         51 . The crack resistant layer of  claim 34  where the bituminous mixture's permeability is greater than 8 cm 2  when tested in accordance with ASTM D 3637. 
     
     
         52 . The crack resistant layer of  claim 34  where the bituminous mixture has a Hveen stability of greater than 21 per ASTM D 1560. 
     
     
         53 . The crack resistant layer of  claim 34  where the bituminous mixture has greater than 1% air voids. 
     
     
         54 . The crack resistant layer of  claim 34  further comprising additives. 
     
     
         55 . The crack resistant layer of  claim 54  where the additives comprise cross-linking agents, accelerators, extenders, fluxing agents, or combinations thereof. 
     
     
         56 . The crack resistant layer of  claim 34  where the aggregate comprises a hard and inflexible mineral aggregate, a hard and inflexible man-made aggregate, or a combination thereof. 
     
     
         57 . The crack resistant layer of  claim 34  where the mixture further comprises recycled materials. 
     
     
         58 . The crack resistant layer of  claim 57  where the recycled materials are reclaimed asphalt pavement, glass, ground rubber tires, ceramics, metals, or mixtures thereof.