微表处理存在的问题

1、Troubleshooting in Micro-Surfacing Emulsion Production and Field,Applications/,微表处乳化沥青生产及施工问题解决方法,2006 ISSA World Congress,Beijing, China,September 6-8, 2006,Bob Jerman,MeadWestvaco Coporation,1,Micro-Surfacing Troubleshooting,/,微表处问题的解决,What is the source of the,problem,？,什么是导致问题产生的原因？,2,Micro-Surf

2、acing Troubleshooting,Motivation/,解决微表处问题的动力,?,We should NOT be looking to place,blame so that we can charge the,offender./,我们不应该通过指责来惩罚,责任人。,?,The goal is NOT to blame someone,else and clear our good name/,目的,不是指责其他人的过失，恢复我们的名,誉,.,3,Micro-Surfacing Troubleshooting,Motivation/,解决微表处问题的动力,When EVERYO

3、NE cooperates in finding the,cause of the problem, the amount of,down time is minimized/,当我们每个人齐心,协力合作找出问题的原因时，停机的时间将,被减到最小。,4,Micro-Surfacing Troubleshooting,Objectives/,微表处问题解决方案的目标,?,Method,approach to problem solving/,方法,解决问题的模式,?,Details/,具体考虑细节,Materials/,工程所用材料,Equipment and Placement/,施工设备和摊

4、铺方,式,Environment/,施工环境,Emulsion Production/,乳化沥青生产,5,Micro-surfacing Troubleshooting,Method/,微表处问题解决的方法,?,Logical Approach/,逻辑上的思路,Weigh “real” data and “fuzzy” data differently/,衡量区,分“真实”数据和“失真”数据,Consider all possibilities/,考虑所有的可能性,Dont avoid the real issue/,不能回避真实的情况,Focus on the primary cause/,

5、注意力集中到主要原因上,Always keep track of time frames/,时刻保持时间纪录,Use documentation and baselines/,参考文献记录以及技,术底限,There is no such thing as “Black Magic”/,没有,“万灵魔,法”,Change one variable at a time/,每次只检测一个变量,6,Micro-surfacing Troubleshooting,Method/,微表处问题解决的方法,?,The big question is “What changed?”/,关键问,题,“,有改变的地

6、方吗？”,“,We have been laying this stuff for 3 years, we,havent changed anything, but suddenly it is,not working”/,“,我们已经利用现在的材料进行微表处,施工,3,年了，没有改变过任何东西，为什么突然不行,了呢,？”,7,Micro-Surfacing Troubleshooting,Method/,微表处问题解决的方法,?,Start going down the list/,从下面的列表开始,-,Aggregate/,石料,-,Materials handling/,原材料处理,-,

7、Mineral filler/,矿物填充料,-,Contamination/,污染,-,Mix additives/,拌合添加剂,-,Surface preparation/,表面处,理,-,Asphalt/,沥青,-,Rain/,降雨,-,Water/,水,-,Humidity,湿度,-,Emulsifier/,乳化剂,-,Sun/shade/,光照,/,荫凉,-,pH,/,酸碱度,-,Wind/,风,-,Polymer/,聚合物,-,Temperature/,温度,-,Calibration/,计量,-,Equipment malfunction/,设备故障,8,Micro-surfaci

8、ng Troubleshooting,Details/,微表处问题解决方法的具体内容,?,Immediate,during emulsion production or during the field,application process/,立即,-,在乳化沥青生产或现场摊铺过程产生的问,题,-,?,Long term,failure that occurs weeks or months later/,长期,-,问题,出现在几个星期或几个月以后,9,Micro-Surfacing Troubleshooting,Details/,微表处问题解决方法的具体内容,?,Materials/,材

9、料,Emulsion (save for last)/,乳化沥青（最后解释）,Aggregate/,石料,?,Changed aggregate source,mineralogy change,reacts differently with a given emulsion/mineral filler,system resulting in lack of work time or slow curing (micro,emulsions are not “one size fits all”)/,变换料源,石料岩性变,化使和特定乳化沥青,/,矿料及矿粉系统反应发生变化，进而导致,缺乏拌合

10、时间以及养护时间变长（微表乳化沥青不是“一个乳,化沥青适合所有系统”）,10,Micro-Surfacing Troubleshooting,Details/,微表处问题解决方法的具体内容,?,Materials (cont.)/,材料,Aggregate (cont.)/,石料,?,New crushing,freshly crushed aggregate has a higher,surface charge than weathered aggregate causing,shorter mix times/,新破碎石料,新破碎石料的表面电荷比堆放,过的石料高，造成可拌合时间变短,?,

11、Different quarry face,not all quarries are equal, and not,all locations within a quarry are equal/,不同料场,不是所,有的料场都是一样的，同一料场内不同地方料源也可能不一样,11,Micro-Surfacing Troubleshooting,Details/,微表处问题解决方法的具体内容,?,Materials (cont.)/,材料,Aggregate (cont.)/,石料,?,Changing clay content,fines content and mineralogy,plays

12、the biggest part in micro-surfacing performance,and effects almost every short and long term,performance parameter/,粘土含量变化,粉料岩性和含量在,微表系统中起着最关键性的作用，它能影响整个系统的短期和,长期性能,?,Changing gradation,can result mix time changes, in,mat deformation, or bleeding of the asphalt in rut filling/,级配变化,导致拌和时间变化，微表处变形或车辙

13、填补泛油,12,Micro-Surfacing Troubleshooting,Details/,微表处问题解决方法的具体内容,?,Materials (cont.)/,材料,Aggregate (cont.)/,石料,?,Fines/clay segregation,causes performance variations,within a single stockpile or load/,细集料,/,矿粉离析,造成同,一堆料或同一批料性能变化,?,Clay contamination,variations in clay content within a,single load cau

14、sed by handling/,粉料污染,/,在运输和处理过,程中造成同一批料的粘土含量产生变化,13,Micro-Surfacing Troubleshooting,Details/,微表处问题解决方法的具体内容,?,Materials (cont.)/,材料,Aggregate (cont.)/,石料,?,Preventative measures,know your source (quarry and,location within quarry), check gradation, sand,equivalent and methylene blue value periodica

15、lly, and,know what your baseline values are for each/,预防性措施,熟悉料源和性质（具体料场及料场内位置），定期检查级配，,砂当量，亚甲蓝值，而且确切知道每个参数的底限,14,Micro-Surfacing Troubleshooting,Details/,微表处问题解决的具体内容,?,Materials (cont.)/,材料,Mineral filler/,矿物填充料,?,Wrong mineral filler type,use the designed type,(cement, lime or alum)/,错误的矿物填充料种类,-

16、,须用设计的,类型（水泥，石灰或硫酸铝）,Wrong cement type,using type IA (air entrained) or,type III (high early strength) can lead to different,results than type I/,错误的水泥型号,-,使用,IA,型号水泥（空,气引入）或者,III,型水泥（高早期强度）造成和,I,型号水泥不,一样的结果,Affects mainly work time, curing rate and,appearance of the mat/,主要影响拌合时间，成型时间,以及路面外观,15,Mic

17、ro-Surfacing Troubleshooting,Details/,微表处问题解决方法的具体内容,?,Materials (cont.)/,材料,Liquid additives/,液体添加剂,?,Wrong chemical or concentration,can effect,work time and curing rate as well as long term,adhesion and wear properties,错误的化学配方或添加,量,会影响拌合时间，成型时间以及长期的粘附和磨耗,性能,Mix water/,外加水,?,Contains rust, sedimen

18、t, or dissolved salts (hard,water),changes work time or curing rate/,含有灰尘，,沉淀以及不溶于水的盐分（硬水）,-,会影响拌合时间及成,型时间,16,Micro-Surfacing Troubleshooting,Details/,微表处问题解决的具体内容,?,Equipment and Placement/,设备和摊铺,Micro-Surfacing machine/,微表摊铺车,?,Incorrect calibration,changes component ratios,resulting in inconsiste

19、nt results or long term performance,failures/,不正确的标定,各种组分比例变化会导致不一致的结,果和长期性能变差,?,Clogged mineral filler chute,not easily noticed but can,have significant effects/,矿粉进料管道堵塞,比较不容易发,现但是有非常显著的影响,?,Worn parts,causes calibration to change over time/,陈,旧部件,随着时间进行导致计量发生变化,17,Micro-Surfacing Troubleshooting,

20、Details,微表处问题解决的具体内容,?,Equipment and Placement (cont.)/,设备和摊铺,Micro-Surfacing machine (cont.)/,微表摊铺车,?,Clogged lines or pumps,produces changes in mix,composition that are difficult to see/,管道或泵堵塞,造成,难以觉察的出料组分变化,?,Contaminated tanks,introduces a component that was,not designed into the system/,乳化沥青贮槽

21、污染,在系统中,引入未知的组分,18,Micro-Surfacing Troubleshooting,Details/,微表处问题解决方法的具体内容,?,Equipment and Placement (cont.)/,设备和摊铺,Micro-Surfacing machine (cont.)/,微表摊铺车,?,Incorrect pug mill mixing action,pug mill type (single,auger vs twin auger) or malfunction causes incomplete,mixing or foaming and splashing/,拌

22、合缸工作不正确,拌合,机类型（单轴,vs,双轴），或者机械故障导致拌合不充分，起泡,或跑浆,?,Lay-down box augers, seals or dead,spots,causes lack of control in the mix placement or,drag marks/,摊铺箱搅拌轴，刮板或死角,造成混合料摊铺控,制不易或有刮痕,19,Micro-Surfacing Troubleshooting,Details/,微表处问题解决的具体内容,?,Equipment and Placement (cont.)/,设备和摊铺,Micro-Surfacing machine

23、(cont.)/,微表摊铺车,?,Preventive measures,periodic recalibration, scheduled,preventive maintenance, cleaning the equipment, and,use of the right equipment designed specifically for,micro-surfacing/,预防性措施,周期性校正，制定预防性养护,时间表，干净的设备和使用微表专用摊铺设备,20,Micro-Surfacing Troubleshooting,Details/,微表处问题解决方法的具体内容,?,Equip

24、ment and Placement (cont.)/,设备和摊铺,Material transport and storage/,材料运输和储存,?,Over-pumping of emulsion,pumps with shearing,surfaces (gear pumps for example) stress emulsions,causing build-up of sieve/,过度剪切,当泵具有剪切的功能,（如齿轮泵），如过度泵送，会造成乳化沥青破乳,?,Stockpile drying and wind exposure,as fines dry and,the stock

25、pile is worked, the fines migrate to the bottom/,堆放干燥及暴露在风中,当细集料变干后，继续堆放时，细料,会向底部迁移,21,Micro-Surfacing Troubleshooting,Details/,微表处问题解决方法的具体内容,?,Equipment and Placement (cont.)/,设备和摊铺,Material transport and storage (cont.)/,材料运输和储存,?,Mineral filler exposed to moisture,cement that is,partially harden

26、ed and then broken up does not,perform the same as dry cement/,水泥部分硬化后再破碎,使用，和未吸过水的水泥的效果完全不一样,?,Stockpile contamination,As little as 0.5% added clay in,one loader bucket can have catastrophic results/,堆料受,污染,在铲车转移过程中引入的微少如,0.5%,的尘土，会产生灾,难性的结果,22,Micro-Surfacing Troubleshooting,Details/,微表处问题解决的具体内容,

27、?,Equipment and Placement (cont.)/,设备和摊铺,Material transport and storage (cont.)/,材料运输和储存,?,Preventive measures,minimize pumping of emulsion,keep stockpiles moist (2%), keep mineral filler out of the,weather, educate loader and screening plant operators,about stockpile placement and management/,?,预防性

28、,措施,尽量减少乳化沥青的泵送次数，保证料堆的含水量,（,2%,）,避免矿粉暴露在空气中，培训铲车手和石料筛分操作,人员关于料堆的堆放和管理知识,23,Micro-Surfacing Troubleshooting,Details/,微表处问题解决的具体内容,?,Equipment and Placement (cont.)/,设备和摊铺,Placement/,摊铺,?,Overworking the mix,working the mix beyond the point,where is should begin to set produces a tender mat/,过度,拌合,过度

29、拌合超过应该硬结的时间点从而导致摊铺后路面强,度下降,?,Mix is too fast (false slurry),mix breaks before final,placement which strips coalescing asphalt film from,aggregate, cures slowly/,拌合太快（假稀浆）,混合料在摊,铺前破乳，造成破乳后的沥青膜剥落，而且强度上升慢,24,Micro-Surfacing Troubleshooting,Details/,微表处问题解决方法的具体内容,?,Equipment and Placement (cont.)/,设备和摊

30、铺,Placement (cont.)/,摊铺,?,Extending work time with water,more likely to runoff of,the emulsion by allowing segregation of aggregate and,emulsion, and produceing a poor surface texture/,加水延,长拌合时间,假稀浆的可能性增加，造成骨料和乳化沥青分离，,路面纹理不理想,?,Surface preparation,mat laid on top of dirty surfaces,loose objects, or

31、over surfaces that provide poor,adhesion/,摊铺前路面处理,摊铺在脏路面，松散物体或粘附,性很差路表,25,Micro-Surfacing Troubleshooting,Details/,微表处问题解决方法的具体内容,?,Equipment and Placement (cont.)/,设备和摊铺,Placement (cont.)/,摊铺,?,Preventive measures,in place of additional water, use,chemical retarder additives or reformulate emulsion

32、 to,improve work time, roughen smooth surfaces such as,pavement markings, and clean oil spots/,预防性措施,路,面事先洒水，使用缓破剂或调整乳化沥青配方来提高工作性能，,粗糙化光滑路标，清理油斑,26,Micro-Surfacing Troubleshooting,Details/,微表处问题解决方法的具体内容,?,Environment/,环境,Temperature/,温度,?,Sudden temperature swings,without a corresponding,emulsion r

33、eformulation/,环境温度突然波动,事先没有相应,的乳化沥青配方调整措施,?,Freeze before total cure,results can range from raveling,to total failure/,在强度形成前结冰,造成裂缝或整体破坏,?,Emulsion temp too high,can cause the work time to be,reduced/,乳化沥青温度过高,造成可拌合时间变短,27,Micro-Surfacing Troubleshooting,Details/,微表处问题解决方法的具体内容,?,Environment (cont.

34、)/,环境,Temperature (cont.)/,温度,?,Preventive measures,watch the weather, plan ahead,and give the emulsion producer enough lead time to,produce the correct emulsion and deliver it at the right,temperature/,预防性措施,密切关注环境温度，预先计划，,提供乳化沥青生产商足够的时间生产和运输配方正确的，温度,正确的乳化沥青,28,Micro-Surfacing Troubleshooting,Detai

35、ls/,微表处问题解决的具体内容,?,Environment (cont.)/,环境,Wind/,风,?,Dust or other material blown onto prepared surface,can prevent proper adhesion of the mat/,灰尘或其它东西,覆盖到预先已清理的路面,阻止微表和路面的粘附,?,Drying the stockpile,increases the likelihood of fines,segregation/,料堆干燥,增加细集料离析的可能性,?,Lack of wind,can decrease drying rat

36、e/,风力太小,降低,微表干燥速度,29,Micro-Surfacing Troubleshooting,Details/,微表处问题解决的具体内容,?,Environment (cont.)/,环境,Wind (cont.)/,风,?,Skinning of the mat,dry wind flash dries the uncured,mat surface trapping water, causes long cure times and,tenderness/,干燥的风使表面变干，使大部分水分无法挥发，,造成养护时间延长，路面变软,?,Preventive measures,thi

37、nk of wind as equivalent to,higher temperature, keep stockpiles moist, and,sweep/blow surface just ahead of lay-down equipment/,预防性措施,将风视为高温，保持料堆润湿，摊铺前清扫路面,30,Micro-Surfacing Troubleshooting,Details/,微表处问题解决的具体内容,?,Environment (cont.)/,环境,Sun/shade/,光照,/,荫凉,?,Increase/decrease in curing rate,may be

38、spotty due to,shade from trees or buildings/,增加,/,降低成型书速度,树木,或建筑产生的阴影会造成成型速度不一致,?,Surface temperature,large factor in work time, curing,rate, asphalt film formation, and drying rate/,路面温度,大大影响拌合时间，成型速率，沥青成膜以及干燥速率,31,Micro-Surfacing Troubleshooting,Details/,微表处问题解决的具体内容,?,Environment (cont.)/,环境,Humi

39、dity/,湿度,?,Drying rate,high humidity slows drying rate/,干燥速率,高湿度降低干燥速率,?,Stockpile drying and segregation,low humidity, even in,the absence of high temperatures, can cause stockpile,problems/,料堆干燥和离析,湿度太低时，即使环境温度不高,也会导致料堆问题,32,Micro-Surfacing Troubleshooting,Details/,微表处问题解决的具体内容,?,Environment (cont

40、.)/,环境,Rain/,雨水,?,Disturbs partially cured mat,does not allow,proper coating of asphalt on aggregate/,破坏部分,破乳的微表处,不利于沥青在石料表面的裹附,?,Preventive measures,rolling or traffic,consolidation prior to rain can help/,预防性措施,下,雨前事先压路机压实或开放交通加固,Night work/,夜间施工,?,Effects of low temp, shade and high humidity all

41、at,once/,低温，荫凉及高湿度在同一时间发生,33,Micro-Surfacing Troubleshooting,Details/,微表处问题解决方法的具体内容,?,Environment (cont.)/,环境,Night work (cont.)/,夜间施工,?,Preventive measures,mix design must take into,account difficult curing conditions, and emulsion,reformulation is usually necessary/,混合料设计时需要将成,型难度考虑进去，而且通常需要乳化沥青配

42、方调整,34,Micro-Surfacing Troubleshooting,Details/,微表处问题解决方法的具体内容,?,Emulsion Composition,Asphalt,（沥青）,?,Inconsistent composition over time,effects emulsion,stability, sieve, mix time, cure rate, adhesion, wear,properties and rutting potential,沥青变化,-,影响乳化沥青的稳,定性，筛上剩余量，拌合时间，成型时间，粘附，磨耗性能和,抗车辙性能,?,Preventi

43、ve measures,know your crude source and,maintain good communication with the asphalt supplier,?,预防方法,-,了解沥青原油的来源，与沥青供应商保持良好的沟通,35,Micro-Surfacing Troubleshooting,Details/,微表处问题解决方法的具体内容,?,Emulsion Composition (cont.)/,乳化沥青组成,Water/,水,?,Contains rust, sediment, or dissolved salts (hard water),these co

44、mponents will act to either stabilize or,destabilize the emulsion/,含有锈蚀物，沉淀，或不溶盐（硬,水）,-,这些物质会使乳化沥青变得太稳定或不稳定,?,Preventive measures,use potable (drinkable) water,test it periodically and treat the water if necessary/,预防,性措施,-,使用饮用水，定期检测，需要时加以处理,36,Micro-Surfacing Troubleshooting,Details/,微表处问题解决的具体内容,

45、?,Emulsion Composition (cont.)/,乳化沥青组成,Emulsifier/,乳化剂,?,Inconsistent chemical composition,causes stability and,performance changes or failures/,化学组成的变化,造成乳,化沥青稳定性及使用性能产生变化，甚至可以造成项目失败,?,Contamination,reduces effectiveness/,污染,降低乳化剂,的活性,?,Preventive measures,ensure the quality of the product,is consi

46、stent over time and watch out for “unscheduled,blends”/,预防性措施,确保乳化剂的质量是一致的，防止“没,有要求过的复配”,37,Micro-Surfacing Troubleshooting,Details/,微表处问题解决的具体内容,?,Emulsion Composition (cont.)/,乳化沥青组成,Acid/,酸,?,Inconsistent concentration,if not controlled, causes pH,fluctuations leading to performance variations/,浓

47、度不一,致,如果失控，可能造成,pH,波动，进而造成性能差异,?,Preventive measures,accurate pH measurement using,calibrated electronic devices (not pH paper) is critical/,预防性措施,pH,计量一定要准确，使用测量准确的电子,pH,计,（不要使用,pH,试纸）,38,Micro-Surfacing Troubleshooting,Details/,微表处问题解决的具体内容,?,Emulsion Composition (cont.)/,乳化沥青组成,Latex/,胶乳,?,Latex

48、stability/coagulum,can cause sieve, uneven,distribution of polymer in the emulsion can cause,changes in residue properties (softening point or cold,ductility) and rutting/,胶乳的稳定性,/,结块,会造成筛分性能,变化，胶乳在乳化沥青中分散不均会导致残留物性能变化（软,化点或低温延度）以及车辙性能,?,Preventive measures,understand the products,handling properties

49、 and stability/,预防性措施,了解产品的,运输性质及稳定性能,39,Micro-Surfacing Troubleshooting,Details/,微表处问题解决的具体内容,?,Emulsion Production/,乳化沥青生产,Emulsifier solution production/,皂液生产,?,Inaccurate measurement,of emulsion component,quantities/,计量不准确,?,Errors in material selection/,材料选择错误,?,Inadequate agitation/,不正确的搅拌,?,E

50、rrors in sampling,emulsifier solution samples,taken for testing prior to complete reaction with,acid/,取样错误,取样测试的皂液还没有和酸反应完全,?,Errors in pH testing/,pH,测试有误,40,Micro-Surfacing Troubleshooting,Details/,微表处问题解决的具体内容,?,Emulsion Production (cont.)/,乳化沥青生产,Emulsifier solution production (cont.)/,皂液生产,?,In

51、correct final solution temperature,can result in poor,emulsion particle size/,皂液温度不准,会造成乳化沥青颗粒,尺寸分布不好,41,Micro-Surfacing Troubleshooting,Details/,微表处问题解决的具体内容,?,Emulsion Production (cont.)/,乳化沥青生产,Emulsifier solution production (cont.)/,皂液生产,?,Preventive measures,have backup measuring devices,availa

52、ble, track material usage, make multiple quality,checks on the solution prior to production, understand,pH test equipment operation, make pH measurements,at room temp, hit target production temps/,预防性措施,预先准备备用的测试仪器，跟踪材料使用情况；在生产前预先,重复检测溶液质量；了解,pH,测试仪器的工作原理，在室温下检,测,pH,值，保证溶液达到要求的温度,42,Micro-Surfacing

53、Troubleshooting,Details/,微表处问题解决的具体内容,?,Emulsion Production (cont.),Mill operation .)/,胶体磨的操作,?,Incorrect ratio,of asphalt and solution,residue and,viscosity changes,不正确的油水比,-,残留物和粘度变化,?,Pump malfunction,or clogged lines,may allow straight,asphalt or emulsifier solution to go to storage,?,泵误工作或堵塞管道,

54、-,可能引起沥青或皂液直接进入成品贮罐,43,Micro-Surfacing Troubleshooting,Details/,微表处问题解决的具体内容,?,Emulsion Production (cont.)/,乳化沥青生产,Mill operation (cont.)/,胶体磨的操作,?,Unsteady operation,temperature or component,fluctuations during operation can produce poor,emulsion quality (can occur over very short time,periods)/,操作

55、不稳定,生产过程中温度或组成的波动导致生产,的乳化沥青质量变低（在很短的时间内的波动就可造成这种结,果）,?,Incorrect configuration,for in-line injection or addition of,solution to asphalt line,may allow cooling of asphalt,prior to entering the mill/,不正确的泵送配置或者将皂液直接,加入沥青管道,可能导致沥青在进入胶体磨前冷却,44,Micro-Surfacing Troubleshooting,Details/,微表处问题解决的具体内容,?,Emul

56、sion Production (cont.)/,乳化沥青生产,Mill operation (cont.)/,胶体磨的操作,?,Incorrect flow rate or mill gap setting, slow mill rotational,speed, rotor/stator wear, or misalignment of rotor/stator,can result in inefficient milling and poor particle size or,sieve/,不正确的流量控制或者胶体磨间隙设置，胶体磨转速太,慢，转子,/,定子磨损或者转子,/,定子不匹配

57、,造成胶体磨效率降,低，颗粒尺寸质量不高，筛分质量不过关,?,Insufficient back pressure,can allow cavitation in the,mill which causes poor particle size, sieve and curing,problems/,负压不充分,能够在胶体磨中造成气穴现象，导致,颗粒尺寸、筛分以及固化速率问题,45,Micro-Surfacing Troubleshooting,Details/,微表处问题解决的具体内容,?,Emulsion Production (cont.)/,乳化沥青生产,Mill operation (cont.)/,胶体磨的操作,?,Different mill,if using multiple mills to supply one job,understand the differences in the emulsion produced by,each/,不同的胶体磨,如果使用不同胶体磨生产乳化沥青来做,同一个项目，必须了解生产出来乳化沥青的区别,?,Particle size,correct size a