微表处理存在的问题

1、1Troubleshooting 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微表处乳化沥青生产及施工问题解决方法2006 ISSA World CongressBeijing, ChinaSeptember 6-8, 2006Bob JermanMeadWestvaco Coporation2Micro-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？3Micro-

2、Surfacing TroubleshootingMotivation/解决微表处问题的动力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.4Micro-Surfacing TroubleshootingMotivation/解决微表处问题的动力解决微表处问题的动力When

3、 EVERYONE 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。5Micro-Surfacing TroubleshootingObjectives/微表处问题解决方案的目标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

4、设备和摊铺方式 Environment/施工环境 Emulsion Production/乳化沥青生产6Micro-surfacing TroubleshootingMethod/微表处问题解决的方法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/衡量区衡量区分分“真实真实”数据和数据和“失真失真”数据数据 Consider all possibilities/考虑所有的可能性考虑所有的可能性 Dont avoid the real issue/不能回避真实的情况不能回避真实的情

5、况 Focus on the primary cause/注意力集中到主要原因上注意力集中到主要原因上 Always keep track of time frames/时刻保持时间纪录时刻保持时间纪录 Use documentation and baselines/参考文献记录以及技参考文献记录以及技术底限术底限 There is no such thing as “Black Magic”/没有没有“万灵魔万灵魔法法” Change one variable at a time/每次只检测一个变量每次只检测一个变量7Micro-surfacing TroubleshootingMethod

6、/微表处问题解决的方法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？”8Micro-Surfacing TroubleshootingMethod/微表处问题解决的方法微表处问题解决的方法 Start going down t

7、he list/从下面的列表开始- Aggregate/石料石料 - Materials handling/原材料处理原材料处理- Mineral filler/矿物填充料矿物填充料 - Contamination/污染污染- Mix additives/拌合添加剂拌合添加剂 - Surface preparation/表面处表面处理理- Asphalt/沥青沥青 - Rain/降雨降雨- Water/水水 - Humidity湿度湿度- Emulsifier/乳化剂乳化剂 - Sun/shade/光照光照/荫凉荫凉- pH/酸碱度酸碱度 - Wind/风风- Polymer/聚合物聚合物-

8、Temperature/温度温度- Calibration/计量计量 - Equipment malfunction/设备故障设备故障 9Micro-surfacing TroubleshootingDetails/微表处问题解决方法的具体内容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

9、期或几个月以后10Micro-Surfacing TroubleshootingDetails/微表处问题解决方法的具体内容微表处问题解决方法的具体内容Materials/材料 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 emu

10、lsions are not “one size fits all”)/变换料源变换料源 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”） 11Micro-Surfacing TroubleshootingDetails/微表处问题解决方法的具体内容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

11、weathered aggregate causing shorter mix times/新破碎石料新破碎石料 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 Different quarry face not all quarries are equal, and not all locations within a quarry are equal/不同料场不同料场 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12Micro-Surfacing TroubleshootingDetails/微表处问题解决方法的具体内容微表处问题解决方法的具体内容Material

12、s (cont.)/材料 Aggregate (cont.)/石料 Changing clay content fines content and mineralogy plays the biggest part in micro-surfacing performance and effects almost every short and long term performance parameter/粘土含量变化粘土含量变化 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 ch

13、anges, in mat deformation, or bleeding of the asphalt in rut filling/级配变化级配变化 导致拌和时间变化，微表处变形或车辙填补泛油13Micro-Surfacing TroubleshootingDetails/微表处问题解决方法的具体内容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

14、细集料/矿粉离析矿粉离析 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 caused by handling/粉料污染粉料污染/在运输和处理过程中造成同一批料的粘土含量产生变化14Micro-Surfacing TroubleshootingDetails/微表处问题解决方法的具体内容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 (q

15、uarry and location within quarry), check gradation, sand equivalent and methylene blue value periodically, and know what your baseline values are for each/预防性措施预防性措施 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15Micro-Surfacing TroubleshootingDetails/微表处问题解决的具体内容微表处问题解决的具体内容Materials (cont.)/材料

16、 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-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 A

17、ffects 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 16Micro-Surfacing TroubleshootingDetails/微表处问题解决方法的具体内容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

18、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, sediment, 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17Micro-Surfacing TroubleshootingDetails/微表处问题解决的具体内容微表处问题解决的具体内容Equipment and Placement/设备和摊铺 Micro-Surfacing

19、 machine/微表摊铺车 Incorrect calibration changes component ratios resulting in inconsistent 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

20、to change over time/陈旧部件 随着时间进行导致计量发生变化 18Micro-Surfacing TroubleshootingDetails微表处问题解决的具体内容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 t

21、anks introduces a component that was not designed into the system/乳化沥青贮槽污染 在系统中引入未知的组分19Micro-Surfacing TroubleshootingDetails/微表处问题解决方法的具体内容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

22、auger) or malfunction causes incomplete mixing or foaming and splashing/拌合缸工作不正确 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 20Micro-Surfacing TroubleshootingDetails/微表处问题解决的具体内容微表

23、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 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

24、 21Micro-Surfacing TroubleshootingDetails/微表处问题解决方法的具体内容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/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

25、化沥青破乳 Stockpile drying and wind exposure as fines dry and the stockpile is worked, the fines migrate to the bottom/堆放干燥及暴露在风中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 22Micro-Surfacing TroubleshootingDetails/微表处问题解决方法的具体内容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 (co

26、nt.)/材料运输和储存 Mineral filler exposed to moisture cement that is partially hardened 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/堆料受堆料受污染污染 在铲车转移过程中引入的微少

27、如0.5%的尘土，会产生灾难性的结果 23Micro-Surfacing TroubleshootingDetails/微表处问题解决的具体内容微表处问题解决的具体内容Equipment and Placement (cont.)/设备和摊铺 Material transport and storage (cont.)/材料运输和储存 Preventive measures minimize pumping of emulsion, keep stockpiles moist (2%), keep mineral filler out of the weather, educate loade

28、r and screening plant operators about stockpile placement and management/预防性预防性措施措施 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24Micro-Surfacing TroubleshootingDetails/微表处问题解决的具体内容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

29、 beyond the point where is should begin to set produces a tender mat/过度拌合 过度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）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 25Micro-Surfacing

30、TroubleshootingDetails/微表处问题解决方法的具体内容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 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/加水延加水延长拌合时间长拌合时间 假稀浆的可能性增加，造成骨料和

31、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 over surfaces that provide poor adhesion/摊铺前路面处理摊铺前路面处理 摊铺在脏路面，松散物体或粘附性很差路表 26Micro-Surfacing TroubleshootingDetails/微表处问题解决方法的具体内容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 Preventi

32、ve measures in place of additional water, use chemical retarder additives or reformulate emulsion to improve work time, roughen smooth surfaces such as pavement markings, and clean oil spots/预防性措施预防性措施 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27Micro-Surfacing TroubleshootingDetails/微表处问题解决方法的具体内容微表

33、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 reformulation/环境温度突然波动环境温度突然波动 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 redu

34、ced/乳化沥青温度过高乳化沥青温度过高 造成可拌合时间变短 28Micro-Surfacing TroubleshootingDetails/微表处问题解决方法的具体内容微表处问题解决方法的具体内容Environment (cont.)/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 r

35、ight temperature/预防性措施预防性措施 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29Micro-Surfacing TroubleshootingDetails/微表处问题解决的具体内容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 th

36、e stockpile increases the likelihood of fines segregation/料堆干燥料堆干燥 增加细集料离析的可能性 Lack of wind can decrease drying rate/风力太小 降低微表干燥速度 30Micro-Surfacing TroubleshootingDetails/微表处问题解决的具体内容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 t

37、rapping 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 think of wind as equivalent to higher temperature, keep stockpiles moist, and sweep/blow surface just ahead of lay-down equipment/预防性措施预防性措施 将风视为高温，保持料堆润湿，摊铺前清扫路面31Micro-Surfacing Troubleshoo

38、tingDetails/微表处问题解决的具体内容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 spotty due to shade from trees or buildings/增加增加/降低成型书速度降低成型书速度 树木树木或建筑产生的阴影会造成成型速度不一致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 formati

39、on, and drying rate/路面温度路面温度 大大影响拌合时间，成型速率，沥青成膜以及干燥速率 32Micro-Surfacing TroubleshootingDetails/微表处问题解决的具体内容微表处问题解决的具体内容Environment (cont.)/环境 Humidity/湿度 Drying rate high humidity slows drying rate/干燥速率干燥速率 高湿度降低干燥速率 Stockpile drying and segregation low humidity, even in the absence of high temperat

40、ures, can cause stockpile problems/料堆干燥和离析料堆干燥和离析 湿度太低时，即使环境温度不高也会导致料堆问题 33Micro-Surfacing TroubleshootingDetails/微表处问题解决的具体内容微表处问题解决的具体内容 Environment (cont.)/环境 Rain/雨水 Disturbs partially cured mat does not allow proper coating of asphalt on aggregate/破坏部分破坏部分破乳的微表处破乳的微表处 不利于沥青在石料表面的裹附 Preventive m

41、easures rolling or traffic consolidation prior to rain can help/预防性措施预防性措施 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 at once/低温，荫凉及高湿度在同一时间发生低温，荫凉及高湿度在同一时间发生 34Micro-Surfacing TroubleshootingDetails/微表处问题解决方法的具体内容微表处问题解决方法的具体内容Environment (cont.)/环境 Night wor

42、k (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方调整35Micro-Surfacing TroubleshootingDetails/微表处问题解决方法的具体内容微表处问题解决方法的具体内容Emulsion Composition Asphalt（沥青） Inconsistent compos

43、ition 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 Preventive 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36Micr

44、o-Surfacing TroubleshootingDetails/微表处问题解决方法的具体内容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 components 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

45、potable (drinkable) water, test it periodically and treat the water if necessary/预防预防性措施性措施-使用饮用水，定期检测，需要时加以处理使用饮用水，定期检测，需要时加以处理 37Micro-Surfacing TroubleshootingDetails/微表处问题解决的具体内容微表处问题解决的具体内容Emulsion Composition (cont.)/乳化沥青组成 Emulsifier/乳化剂 Inconsistent chemical composition causes stability and

46、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 consistent over time and watch out for “unscheduled blends”/预防性措施预防性措施 确保乳化剂的质量是一致的，防止“没有要求过的复配” 38Micro-Surfacing Troublesho

47、otingDetails/微表处问题解决的具体内容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

48、paper) is critical/预防性措施预防性措施 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） 39Micro-Surfacing TroubleshootingDetails/微表处问题解决的具体内容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 stability/coagulum can cause sieve, uneven distribution of polymer in the emulsion can cause changes in residue propertie

49、s (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 and stability/预防性措施预防性措施 了解产品的运输性质及稳定性能 40Micro-Surfacing TroubleshootingDetails/微表处问题解决的具体内容微表处问题解决的具体内容 Emulsion Production/乳

50、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/材料选择错误材料选择错误 Inadequate agitation/不正确的搅拌不正确的搅拌 Errors in sampling emulsifier solution samples taken for testing prior to complete reaction with acid/取样错误取样错误 取样测试的皂液还没

51、有和酸反应完全 Errors in pH testing/pH测试有误测试有误 41Micro-Surfacing TroubleshootingDetails/微表处问题解决的具体内容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 Incorrect final solution temperature can result in poor emulsion particle size/皂液温度不准皂液温度不准 会造成乳化沥青颗粒尺寸分布不好 42Micro-

52、Surfacing TroubleshootingDetails/微表处问题解决的具体内容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 available, track material usage, make multiple quality checks on the solution prior to production, understand pH t

53、est equipment operation, make pH measurements at room temp, hit target production temps/预防性措施预防性措施 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43Micro-Surfacing TroubleshootingDetails/微表处问题解决的具体内容微表处问题解决的具体内容Emulsion Production (cont.) Mill operation .)/胶体磨的操作 Incorrect ra

54、tio 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-可能引起沥青或皂液直接进入成品贮罐44Micro-Surfacing TroubleshootingDetails/微表处问题解决的具体内容微表处问题解决的具体内容Emulsion Production (cont.)/乳化沥青生

55、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)/操作不稳定操作不稳定 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

56、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 45Micro-Surfacing TroubleshootingDetails/微表处问题解决的具体内容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 Incorrect flow rate or mill gap setting, slow mill

57、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，转子慢，转子/定子磨损或者转子定子磨损或者转子/定子不匹配定子不匹配 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 th

58、e mill which causes poor particle size, sieve and curing problems/负压不充分负压不充分 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46Micro-Surfacing TroubleshootingDetails/微表处问题解决的具体内容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 Par