TECHNICAL INFORMATION FOR ULTRACOTE

POLYMERIC AGGREGATE TREATMENT

"THE RAINCOAT FOR YOUR ROCKS"

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TABLE OF CONTENTS

Description of Ultracote

Typical Specification With ASTM Referrals

Construction Guide For Field Application of Polymeric Anti-Strip

Laboratory Preparation Of Hot Mix Specimens

Appendix A ASTM D 244 Revisions

Appendix B Paving Projects

ULTRACOTE
(UP-5000)

Polymeric Aggregate Treatment
(Latex Emulsion)

Environmental concerns and performance
of existing anti-stripping treatments
are two of the reasons that
Ultrapave developed the
ULTRACOTE
polymeric anti-strip system.

The POLYMERIC AGGREGATE TREATMENT system shall consist of a Polymeric SBR Latex Emulsion concentrate (Ultracote), a metering device, and an application apparatus.

The Ultracote concentrate, when used as an anti-strip material, shall conform to the physical characteristics listed in Table 1 of Section 1 of this specification. The metering device shall conform to the requirements listed in Section 4. The application apparatus shall conform to the requirements listed in Section 5. Chip Seal aggregate metering and application requirements are listed in Appendix B.

1. MATERIAL CHARACTERISTICS:

   Material Characteristic	Minimum	Maximum	Test Method
   Solids Percent	65.0	72.0	ASTM 1417 Section 4
   Residual Styrene, PPM	-	1,000	ASTM 1417 Section 5
   pH	9.75	11.25	ASTM D 1417 Section 6
   Brookfield viscosity, Spindle 2, 20 RPM, cPs	-	2,000	ASTM D 1417 Section 8
   * See Appendix A for text of modified test method.

2. REDUCTION TO 15.0% LATEX SOLIDS

   The Ultracote concentrate shall be diluted with water to a 15% latex solids material by the metering device prior to delivery to the aggregate through the application apparatus.

3. QUALITY OF WATER USED TO REDUCE ULTRACOTE SOLIDS TO 15%

   Water used to reduce Ultracote solids to 15% shall be free from all visible contamination. Testing for pH, hardness, etc. will not be required.

4. METERING DEVICE

   The metering device shall have two positive displacement pumps, one for water and one for Ultracote concentrate, which discharge into a pipe or hose. The device shall be equipped with a computer control system capable of processing an electronic signal, from an aggregate belt scale, which will adjust liquid flow rates to correspond to aggregate feed rate. The computer control panel shall provide a means for adjustment of percent of 15% solids Ultracote applied to the aggregate, aggregate moisture content, and the Ultracote concentrate to water ratio. A certifiable readout display shall be provided for polymeric SBR latex emulsion concentrate, water and aggregate. The readout shall display percent, rate per time and total units delivered for each of those parameters. The Ultracote concentrate and water readout units may be in gallons, pounds of liquid or tons of liquid delivered. The aggregate units will be in tons. The readout shall also be capable of displaying these values in metric units.

   The combined pump discharge shall be connected to the application apparatus located directly above the aggregate feed belt at the entrance to the dryer drum. 2 valves shall be provided in the combined discharge line to permit sampling of the 65% solids and the 15% solids.

5. APPLICATION APPARATUS

   The application apparatus shall consist of a short (12 to 16 inch) section or sections of ¾" or 1" hose attached to the end of the conduit which delivers the diluted Ultracote latex emulsion material to the aggregate stream. The application apparatus shall be adjusted to allow the unattached end of the hose to ride on the top surface of the aggregate stream. A single hose application is appropriate for discharge into a pugmill application.

6. APPLICATION OF POLYMERIC AGGREGATE TREATMENT

   The 15% solids Ultracote shall be applied to the aggregate stream at the collection hopper just prior to entry into the dryer drum. Physical mixing of Ultracote and aggregate shall be accomplished by the turbulence inside the dryer drum and/or pugmill.

7. TEMPERATURE

   A minimum temperature of 250°F (121°C) shall be attained by the aggregate and Ultracote materials to properly dehydrate and set the latex solids, prior to applying asphalt cement.

8. AGGREGATE MOISTURE

   Aggregate moisture contents shall normally range from 0.5% to 8.0% at the time of application of the 15% solids Ultracote material. Actual aggregate moisture shall be determined and the percent entered in the control panel. Aggregate moisture content variations within plus or minus 3.0 percent will not significantly alter Ultracote application rates.

9. APPLICATION RATES

   Application rates of the 15% solids Ultracote material shall range between 0.6667% and 0.0833% by weight of aggregate for polymeric aggregate treatments. Values for Ultracote and water to be entered into the control panel should be selected from this table.

   APPLICATION RATES
   65% Concentrate diluted 3.3333:1 with water by weight to 15% Latex Solids
   Mix Design Application Rate @ 15% Solids per Ton of Aggregate	Value to be entered for Percent Ultracote Concentrate	Value to be entered for Percent Water	Percent Latex Solids Coating	Dry Pounds Latex per Ton of Aggregate
   0.6667	0.1476	0.5191	0.1000	2.00
   0.5833	0.1291	0.4542	0.0875	1.75
   0.5000	0.1107	0.3893	0.0750	1.50
   0.4167	0.0922	0.3245	0.625	1.25
   0.3333	0.0738	0.2595	0.0500	1.00
   0.2500	0.0553	0.1947	0.0375	0.75
   0.1667	0.0369	0.1298	0.0250	0.50
   0.0833	0.0184	0.0649	0.0125	0.25

CONSTRUCTION GUIDE

FOR FIELD APPLICATION
OF POLYMERIC ANTI-STRIP

The following is a construction guide for field application of Ultracote anti-strip system to aggregates at the hot plant.

1. REDUCTION TO 15% LATEX SOLIDS:

   The Ultracote concentrate contains 65% latex solids and must be diluted to 15% latex solids prior to use. Mix one Ultracote concentrate with 3.3 parts water. This is accomplished automatically when using an Ultrapave approved application unit. The added water serves as a carrier to help distribute the latex emulsion throughout the aggregate particles. (Please see item 8 below for additional information about ratios of water to latex emulsion.)

2. MIXING AND METERING DEVICE

   The Ultrapave approved application pump unit, described on page 5, is used to meter and mix the Ultracote concentrate and water together to form a uniform 15% latex solids emulsion that is applied to the aggregate.

3. INCORPORATION WITH AGGREGATE

   The diluted latex emulsion should be applied to the aggregate stream at the collection hopper just prior to entry into the dryer drum. Very little mechanical agitation of the aggregate is required to properly disperse the latex emulsion due to the osmotic character of Ultracote. The mixing begins as the materials enter the dryer and is completed by the turbulence inside the dryer drum.

4. TEMPERATURE

   The aggregate, after addition of the latex emulsion, should be allowed to reach a minimum temperature of 250° F (121° C) prior to applying asphalt cement to properly dehydrate and set the latex emulsion solids.

5. CONFIRMATION CHECK

   A one-time check for assurance that the diluted latex emulsion is being deposited on the aggregate should be made prior to production of the asphalt concrete mixture. A small "dry batch" of at least one ton of aggregate should be made, at the anticipated production rate. This will provide a production blend of aggregate and Ultracote, without asphalt. Remove several of the 1/4" (or larger) stones and apply a drop of water with an eyedropper to them. Repeat the process with several similar stones, that have been oven dried, but not treated. A visual examination of the water drop on the treated stone face should appear as on a "waxed surface", while the untreated stone should not be resistant to water penetration.

6. RETAINED STRENGTH

   A one-time check for retained strength may be made after production of the asphaltic mixture is begun. This is to assure that the laboratory predictions are accomplished.

7. AGGREGATE MOISTURE

   Aggregate moisture contents from 0.5 to 8.0 percent are acceptable at the time of application of the diluted Ultracote emulsion. When aggregate moisture rates are outside these limits it may be necessary to adjust the ratio of water to Ultracote concentrate, up or down slightly, to provide proper dispersion of the latex emulsion on the aggregate. Actual aggregate moisture content, plus or minus 3.0 percent of target will not significantly alter the latex emulsion application rates.

8. APPLICATION RATES FOR THE CONTROL UNIT

   Application rates of the 15% solids Ultracote material shall range between 0.6700% and 0.0838% by weight of aggregate for polymeric aggregate treatments. Values for Ultracote and water to be entered into the control panel should be selected from Table 3 at the end of this section.

9. SAMPLING PROCEDURE

   This sampling procedure is applicable only for the determination of solids content of the diluted Ultracote concentrate material applied to the aggregate. Samples for determining the Ultracote concentrate characteristics must be obtained from the supply line to the application unit.

   Samples of the diluted Ultracote material (15% solids) may be obtained from the sample valve in the discharge line of the application unit. The sample is to be obtained only while the unit is operating and at least five minutes after startup. Draw and discard approximately one quart of material to flush any contaminants from the valve before obtaining the sample. Using a new and clean one-pint container having a tight fitting screw cap, draw a one-pint sample. Care should be taken to prevent contamination of the sample container and contents before, during and after sampling. The filled container should be cleaned only with a clean, dry cloth. The sample container should be marked to indicate the "what, where and when" of the sample.

   When sampling Ultracote concentrate use the procedure for sampling emulsified asphalt described in AASHTO T-40, except that the sample size may be modified to one quart of material.

10. SAMPLE TESTING FOR PERCENT SOLIDS

    The sample of 15% solids material obtained (as described in item 9 above) can be tested for solids content using the following method. Shake the sample to assure uniform suspension of the solids, and then pour out approximately 100 grams of the liquid into a pre-weighed metal pie plate. (All weights should be determined to the nearest 0.1gram.) Dehydrate the sample in an oven at 248º F (120º C) for 24 hours and re-weigh the plate and sample. Calculate solids percent as follows:

    100 - (E/C) x 100 = percent solids

    Where:
        A = weight of plate
        B = weight of plate and sample before dehydration
        C = weight of original sample
        D = weight of sample after dehydration
        E = weight loss

11. CONVERSION FACTORS

    To convert from gallons of Ultracote concentrate to wet pounds of Ultracote concentrate multiply by 8.0.

    To convert from wet pounds of Ultracote concentrate to gallons divide by 8.0.

    To convert from wet pounds of Ultracote concentrate to dry pounds of latex solids multiply by 0.65 (65.0%).

    To convert from gallons Ultracote concentrate to dry pounds of latex applied to the aggregate, multiply by 1.2 (Gallons x 8 pounds x 0. 15 {or 15%) = 1.2).

     

    CONVERSION FACTORS TABLE 3
    65% Concentrate diluted 3.3333:1 with water by weight to 15% Latex Solids
    Mix Design Application Rate @ 15% Solids per Ton of Aggregate	Value to be entered for Percent Ultracote Concentrate	Value to be entered for Percent Water	Percent Latex Solids Coating	Dry Pounds Latex per Ton of Aggregate
    0.6667	0.1476	0.5191	0.1000	2.00
    0.5833	0.1291	0.4542	0.0875	1.75
    0.5000	0.1107	0.3893	0.0750	1.50
    0.4167	0.0922	0.3245	0.625	1.25
    0.3333	0.0738	0.2595	0.0500	1.00
    0.2500	0.0553	0.1947	0.0375	0.75
    0.1667	0.0369	0.1298	0.0250	0.50
    0.0833	0.0184	0.0649	0.0125	0.25

HOT MIX SPECIMENS

Ultracote is a Polymeric SBR Latex emulsion, that is diluted to 15% latex solids, and applied to the aggregate prior to coating with asphalt. The following procedure should be used for preparing laboratory specimens to be used for mix design or stripping tests of asphalt concrete hot mix.

It is recommended the determination of optimum asphalt content be made with aggregates treated with Ultracote UP-5000."

1. The latex concentrate emulsion as received has 65% latex solids. It must be diluted prior to use. It is typically diluted to 15% for use at the hot mix plant, however it is recommended that it be diluted to 5% to allow easier measuring and mixing in the laboratory. To dilute, mix one part latex emulsion concentrate with 12 parts water by weight and stir gently, as per instructions in number 2 below.

   DILUTION INSTRUCTIONS Table 4
   Mix Design Application Rate @ 15% Solids per Ton of Aggregate	Grams of 65% Ultracote Concentrate	Grams of Water	Grams of 5% Ultracote Emulsion per 1200 Grams of Aggregate for Testing	Pounds of Polymer Latex Solids per ton of Hot Mix
   0.6667	1.8462	22.1538	24	2.00
   0.5833	1.6154	19.3846	21	1.75
   0.5000	1.3846	16.6154	18	1.50
   0.4167	1.1538	13.8462	15	1.25
   0.3333	0.9231	11.0769	12	1.00
   0.2500	0.6923	8.3077	9	0.75
   0.1667	0.4615	5.5385	6	0.50
   0.0833	0.2308	2.7692	3	0.25

2. Reduction of solids to 5% is accomplished using the following steps:
   1. Select, from column 4 of Table 4, the weight of 5% material for the dosage rate you will use

      NOTE: You must adjust the weight for samples of other than 1,200 grams. To do this you can use the following formula:
      Sample size / 1,200 grams x 5% weight (from column 2)

   2. Multiply this adjusted weight by the number of samples you will treat to calculate the total weight of dilute Ultracote 5% solids liquid. Multiply this total weight by 1.5 to arrive at the total weight you should prepare for this work session. This provides for an extra amount, if needed, and allows for easier and more consistent mixing. For instance, assume you will treat 6 samples at 1.0 pound of polymer per ton of aggregate. From the chart you will determine that each sample will require 12 grams, for a total of 72 grams (6 samples x .12 grams per sample = 72 grams). Then multiply the 72 grams by the 1.5 factor for a total of 108 grams of diluted material that you should make up for this work session.
   3. Because it can be difficult to-weigh this small quantity, you may measure by volume if you correct the volume for specific gravity. The specific gravity of water is one; that is, 1 gram of water is equal to 1 ml or 1 cc. The specific gravity of the 65% solids concentrate averages 0.96, so the volume is slightly greater than the weight. To calculate the volume divide the weight by the specific gravity (for example, 12 grams divided by 0.96 = 12.5 ml or cc).
   4. Suction the required amount of 65% solids material into a pipette and then discharge it into a small beaker. In a like manner, transfer the required amount of water into the beaker with the pipette. This will flush the residue polymer from the pipette while measuring the water volume.
   5. Stir the mixture gently with a small spatula until mixed.
3. Aggregate which has been air or oven dried should be pre-wetted prior to application of the Ultracote anti-strip material. The amount of pre-wet water will vary, depending upon the water absorption characteristics of the aggregate, but will probably be in the 3 to 5 percent range. The pre-wetting should produce a damp or darkened color, but not a shine to the aggregate surface.
4. Add the appropriate amount of diluted latex emulsion to the pre-wetted aggregate. Use a pipette to measure the proper amount of diluted latex emulsion to produce the required polymer latex solids for the desired application rate. Application rates for polymeric aggregate treatments typically range between 0.6667% and 0.0833% by weight of aggregate and are determined based upon laboratory testing for loss of strength in the presence of moisture. Greater amounts may be necessary for more pronounced stripping conditions.
5. Mix the latex emulsion coated aggregate blend sample thoroughly.
6. Place the sample into an oven; heat to the temperature prescribed by the test method. As soon as the aggregate reaches that prescribed temperature, prepare asphalt mix specimens.

   (Note: If the asphalt hot mix is to be prepared at a later date, store the polymer-treated aggregates in sealed plastic bags. DO NOT LEAVE LATEX EMULSION TREATED AGGREGATE IN OVEN OVERNIGHT OR FOR LONG PERIODS OF TIME).

7. Follow mix design procedures as describe in the method being used. Mixes prepared for the latex emulsion treated aggregates may require a greater compaction effort in the laboratory than that which is not treated to achieve the desired 5-7% voids.
8. Report the level of treatment as a percent of latex emulsion @ 15% solids on the basis of dry aggregate weight. This figure, when multiplied by the 15% value, is the percent of dry polymer latex solids applied to the aggregate.

ASTM D 244

Revise Sections 39 through 44 as follows:

39. SCOPE

39.1 This test method measures the chemical breaking of the latex emulsion

40. SIGNIFICANCE AND USE

40.1 This test method is used to identify the amount of available latex solids that is broken from the emulsion by utilizing specified amounts and concentrations of calcium chloride solution.

41. APPARATUS AND REAGENTS

41.1 Wire cloth - An 80 mesh sieve having wire diameters and openings tht conform to Specification E 11.

41.2 Beaker - A metal beaker of 600 ml capacity.

41.3 Rod - A metal rod with rounded ends, approximately 5/16 in. (7.9 mm) in diameter.

41.4 Buret - A 50 ml glass buret graduated in 0.1 ml intervals.

41.5 Delete in total.

41.6 Calcium Chloride Solution (5.55 g/l) - Dissolve 5.55 g of calcium chloride (CaCl2) in water and dilute to 1 l. The 5.55 g/l calcium chloride solution shall be standardized to be a 0.01 N +/- 0.001 normal solution of calcium chloride in water.

41.7 Delete in total.

41.8 Balance - capable of weighing 500 g to within +/- 0.1 g.

42. PROCEDURE

42.1 Determine the percentage of solids in accordance with ASTM D 1417, Section 4.

42.2 Record the weight of the 80 mesh sieve.

42.3 Weigh 100 +/- 0.1 g of emulsified latex into the 600 ml beaker. Bring the wieghed sample of emulsion and the proper reagent to a temperature of 77 +/- 1.0°F (25 +/- 0.5°C). Over a period of approximately 2 min., add to the beaker, from a buret, 50 ml of Calcium Chloride solution (5.55 g/l). While adding the Calcium Chloride solution, stir the contents of the beaker continuously and vigorously, kneading any lumps against the sides of the beaker to ensure thorough mixing of the reagent with the emulsion. Continue kneading the lumps for an additional 2 min. after the addition of the Calcium Chloride solution.

Note 11 - Delete in total.

42.4 Decant the mixture of any unbroken emulsion and reagent onto the 80 mesh sieve. Rinse the beaker containing the sample and metal rod with distilled water. Knead and break up all lumps, and continue washing the beaker, rod, and sieve. Place the sieve, and any cagulum in a 325°F (163°C) drying oven and dry to constant weight.

43. CALCULATION

43.1 Subtract the tare weight of the sieve from the weight of the dried sieve and coagulum to obtain the percent retained. Calculate the percent retained on an 80 mesh sieve as follows:

Percent retained = (A/B) * 100

Where:

A = weight of coagulum on 80 mesh sieve, and
B = weight of original latex emulsion.

44. Delete in total.

Ultracote Projects

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