TAKING FIBERS TO THE NEXT LEVEL
ASPHALT | SEALCOATING | GEN 3
FIBERS: LET US TAKE YOUR MATERIAL TO THE NEXT LEVEL
WE ARE A DISTRIBUTOR FOR CREAMIX.
High asphalt content mixes like SMA and OGFC require careful mixing and placement. In order to prevent the asphalt from draining down over the aggregate, a small percentage of CreaMix Cellulose Fibers are used to thicken and stabilize the mix. The cellulose functions by expanding and interlocking to form a matrix that holds the asphalt in place and prevents migration during production, transportation and compaction.
What is SMA – Stone Mastic Asphalt?
Stone mastic asphalt (SMA), also called stone-matrix asphalt, provides a deformation-resistant, durable surfacing material, suitable for heavily trafficked roads, residential streets and highways. SMA has a high coarse aggregate content that interlocks to form a stone skeleton that resists permanent deformation. The stone skeleton is filled with a mastic of bitumen and filler to which fibres are added to provide adequate stability of bitumen and to prevent drainage of binder during transport and placement.¹
Photo Source: https://tti.tamu.edu/researcher/thin-is-in-thin-asphalt-overlay-helps-stretch-budgets-further/
What is OGFC – Open-Grade Friction Course?
Open-graded friction course (OGFC) is used to improve the surface frictional resistance of asphalt pavements. OGFC improves wet weather driving conditions by allowing the water to drain through its porous structure away from the roadway. The improved surface drainage reduces hydroplaning, reduces splash and spray behind vehicles, improves wet pavement friction, improves surface reflectivity, and reduces traffic noise.²
CreaMix is well-known in the industry. Nationally CreaMix has been used in numerous projects since 1994. CreMix is a current member of NAPA and MAA. Contractor references are available on request.
States with projects containing CreaMix fibers include:
Building Roads into the Future
Future road building will center on key hot mix technologies that provide driver safety and road surface longevity. Two mixes leading the way in Perpetual Pavement concepts are Stone Matrix Asphalt (SMA) and Open Grade Friction Courses (OGFC). Both mixes rely on CreaMix as a stabilizer during production and placement.
SMA is a gap graded mix containing increased amounts of coarse aggregate, mineral filler and asphalt cement as well as decreased amounts of fine aggregate and sand. The technology of SMA can be broken into two sections, the skeleton and the mortar.
Stone-on-stone contact is the foundation of the SMA “skeleton.” This design provides an efficient load distribution network. Coarse aggregate is used, while flat and elongated particles must be avoided.
The “mortar” is rich mastic containing mineral filler, asphalt cement and fiber. In order to coat the entire skeleton and hold the coarse aggregate in place, a high amount of asphalt is used. This mortar must be stabilized to prevent drain-down from occurring.
CreaMix is introduced into the mix at 0.2 to 0.4% of the total mix to prevent drain-down and to ensure a homogeneous mixture.
Increased pavement life of 30 to 40 percent
Less rutting and cracking
Improved resistance to raveling and fatigue
Reduced spray in wet conditions
Improved frictional resistance
OGFC or Porous Friction Courses (PFC) are open mixes with interconnecting voids that provide drainage during rainfall. The rainwater drains vertically through the road surface to an impermeable, underlying layer and then laterally to the day-lighted edge of the OGFC.
These roads offer many safety advantages:
Improved visibility in heavy rainfall
Less road spray in wet conditions
CreaMix is available in a loose fiber form as well as in pellets. In the manufacture of CreaMix a unique procedure is used to create coarse fibers containing high fiber content. Once introduced into the mix, monomolecular adhesion between the asphalt cement and the surface of the mineral modified fiber occurs. As a result, an interlocking matrix is created which holds the asphalt in place and prevents migration during production, transportation, laying and compaction of the mix.
CreaMix is available in two forms for ease of use and mix dispersion:
1) CreaMix TC 1004
Meets nationally recognized standards for particle size distribution
Post consumer fiber
Packaged in 1,000-pound Big Bags
Easy, clean dosing
Simple to handle and store
Photo of cellulose fiber
2) CreaMix TPC Pellets
Packaged in 1100 lb bags and 50 lb bags
Very clean dosing
Easy handling and storage
The reclaimed cellulose fibers (gray fibers) play an important role in the add mix of asphalt emulsion base sealcoat. The fibers help when mixing polar and non-polar components in the add mix to hold them together. In addition, the fibers play a critical role in the curing process. As the fibers release water, the microscopic space close allowing a chemical process to take place allowing the sealcoat to dry.
There are many different grades of fibers used in making sealcoat. The grade and type of fiber is determined by the formulator based on their individual add mix. In the table below you will see there are many types of fibers for each grade. CreaFill makes is simple. It has three grades and one fiber for each. Below is a replacement guide for cellulose fibers.
Many sealcoaters use a number of bag addition per add mix. This is based on the weight of the bags. For your review, we have also included the packaging configuration to assist in your formulation.
Gen 3 is designed to reduce and/or replace cellulose fibers only in sealcoat. It is not a replacement for any of your other add mix material. Asphalt emulsion-based sealcoat uses gray fibers to add viscosity, mix polar material and add in curing of the seal. Gen 3 uses natural products to reduce and/or replace cellulose fibers. Containing no cellulose fibers, it can greatly reduce bacteria bloom and may lower the amount of biocide used.
Each sealcoat manufacture has its own add mix and order of addition. We recommend adding Gen 3 with your oil-based material. No claim is made on the exact amount of Gen 3 addition. Testing is required to determine your desired result. Small batch testing is highly recommended. For most sealcoat formulations a starting point of 10 lbs. of Gen 3. This makes on average 1,000 gallons of finished sealcoat.
The addition of Gen 3 to your add mix is done while the mixer is agitating the oil-based material. Disperse the entire amount of Gen 3 rapidly and evenly over the surface. More is not better. The addition of high amounts of Gen 3 will cause undesirable outcome such as clumping and binding. Too much could cause clogging issue with the spray pump or clumping of sealcoat when applied with a squeeze. A small amount of Gen 3 yields great results, reduce the amount of gray fibers, shipping cost and storage space.
Gen 3 contains no cellulose fiber. We make no claim by replacing cellulose fibers with Gen 3 you can reduce measures to prevent bacterial growth. Changes made to your preventative measures should be done only after testing.