微表处乳化沥青生产及施工问题解决方法(吕紫剑)

Troubleshooting in Micro-SurfacingEmulsion Production and Field Applications/微表处乳化沥青生产及施工问题解决方法吕紫剑MeadWestvaco/美德维实伟克公司1Micro-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？2Micro-Surfacing TroubleshootingMotivation/解决微表处问题的动力When 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。

3Micro-Surfacing TroubleshootingObjectives/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/施工设备和摊铺方式–Environment/施工环境–Emulsion Production/乳化沥青生产4Micro-surfacing TroubleshootingMethod/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–Don’t avoid the real issue/不能回避真实的情况–Focus on the primary cause/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”/“万灵魔法”–Change one variable at a time/每次只检测一个变量5Micro-surfacing TroubleshootingMethod/微表处问题解决的方法•The big question is “What changed?”/关键问题……“什么地方改变了吗？”–“We have been laying this stuff for 3 years, we haven’t 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？”6Micro-Surfacing TroubleshootingMethod/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-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7Micro-surfacing TroubleshootingDetails/微表处问题解决方法的具体内容•Immediate–during emulsion production or during the fieldapplication 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8Micro-Surfacing TroubleshootingDetails/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 reactsdifferently with a given emulsion/mineral filler system resultingin 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/矿料及矿物填充料拌合时会导致缺乏拌合时间或者养护时间变长（微表乳化沥青不是“一个乳化沥青适合所有系统”）9Micro-Surfacing TroubleshootingDetails/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 highersurface charge than weathered aggregate causing shorter mixtimes/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 alllocations within a quarry are equal/不同料场–不是所有的料场都是一样的，料场内不同地方料源也可能不一样10Micro-Surfacing TroubleshootingDetails/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 playsthe biggest part in micro-surfacing performance and effectsalmost every short and long term performance parameter/改变粉料含量–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 matdeformation, or bleeding of the asphalt in rut filling/改变骨料的级配–能够导致拌合时间的改变，在车辙填补过程中再次出现车辙或泛油11Micro-Surfacing TroubleshootingDetails/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 variationswithin a single stockpile or load/细集料/粉料离析–造成同一堆料或同一批料性能变化•Clay contamination–variations in clay content within asingle load caused by handling/粉料污染/在处理过程中造成同一批骨料中粉料含量发生变化1213Micro-Surfacing Troubleshooting Details/微表处问题解决方法的具体内容•Materials (cont.)/材料–Aggregate (cont.)/骨料•Preventative measures –know your source (quarry and location within quarry), check gradation, sand equivalent and methylene blue value periodically, and know what yourbaseline values are for each/预防性措施–熟悉料源（料场及料场位置），定期检测骨料的级配，砂当量和亚甲蓝，并确切知道每项检测所要求的指标范围14Micro-Surfacing TroubleshootingDetails/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)/错误的矿物填充料的类型-使用设计的类型（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（较高早期强度）与I 型号水泥相比造成不一样的结果–Affects mainly work time, curing rate and appearance of the mat/主要影响拌合时间，养护速率以及路面外观Micro-Surfacing TroubleshootingDetails/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 timeand curing rate as well as long term adhesion and wearproperties错误的化学性质或浓度–会影响拌合时间，养护速率以及长期的粘聚力和磨耗性能–Mix water/水•Contains rust, sediment, or dissolved salts (hard water)–changes work time or curing rate/含有铁锈，沉淀物或者水溶性的无机盐（硬水）-会影响拌合时间及固化速率15Micro-Surfacing TroubleshootingDetails/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 resultingin inconsistent results or long term performance failures/错误的标定–导致各种组分比例发生变化与设计结果不一致或者长期路用性能变差•Clogged mineral filler chute–not easily noticed but canhave significant effects/矿物填充料进料管道堵塞–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/磨损部件–随着时间的过去会引起标定结果偏移16Micro-Surfacing TroubleshootingDetails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 mixcomposition 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 notdesigned into the system/储罐污染–引入设计中未涉及组分17Micro-Surfacing TroubleshootingDetails/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 (singleauger vs twin auger) or malfunction causes incomplete mixingor foaming and splashing/拌合箱内不正常拌合行为–拌合箱类型（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 deadspots–causes lack of control in the mix placement or dragmarks/摊铺箱搅拌轴，刮板或死角–造成对混合料缺乏控制或有拖痕18Micro-Surfacing TroubleshootingDetails/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•Preventive measures–periodic recalibration, scheduledpreventive maintenance, cleaning the equipment, and use ofthe right equipment designed specifically for micro-surfacing/预防性措施–周期性再次标定，制定预防性养护时间表，注意设备的清洁和选用正确的微表专用摊铺设备19Micro-Surfacing TroubleshootingDetails/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-upof sieve/过度甭送乳化沥青–当用具有剪切的功能（如齿轮泵）的泵泵送乳化沥青，会造成乳化沥青粒径变粗•Stockpile drying and wind exposure–as fines dry and thestockpile is worked, the fines migrate to the bottom/料堆干燥及暴露在风中–当细集料变干后，继续堆放时，细料会向底部迁移20Micro-Surfacing TroubleshootingDetails/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 partiallyhardened and then broken up does not perform the same asdry cement/矿物填充料受潮–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 inone loader bucket can have catastrophic results/堆料受污染–引入微少哪怕只有0.5%的粘土，都会产生灾难性的结果21Micro-Surfacing TroubleshootingDetails/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, keepstockpiles moist (>2%), keep mineral filler out of the weather,educate loader and screening plant operators about stockpileplacement and management/•预防性措施–尽量减少乳化沥青的泵送次数，保证料堆的含水量（>2%）, 避免矿物填充料暴露在空气中，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22Micro-Surfacing TroubleshootingDetails/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 pointwhere 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无强度•Mix is too fast (false slurry)–mix breaks before finalplacement 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23Micro-Surfacing TroubleshootingDetails/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 ofthe emulsion by allowing segregation of aggregate andemulsion, and produceing a poor surface texture/加水延长拌合时间–可能导致跑浆，造成骨料和乳化沥青之间的离席，从而影响路面纹理•Surface preparation–mat laid on top of dirty surfaces, looseobjects, or 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24Micro-Surfacing TroubleshootingDetails/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, usechemical retarder additives or reformulate emulsion toimprove work time, roughen smooth surfaces such aspavement markings, and clean oil spots/预防性措施–用化学缓破剂或调整乳化沥青配方来替代外加水延长拌合时间，打毛光滑路面就像路面的标记，清理油斑25Micro-Surfacing TroubleshootingDetails/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 correspondingemulsion reformulation/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 tototal failure/在强度完全前结冰–造成裂缝或整体破坏•Emulsion temp too high–can cause the work time to bereduced/乳化沥青温度过高–造成拌合时间变短26Micro-Surfacing TroubleshootingDetails/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, andgive the emulsion producer enough lead time to produce thecorrect 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27Micro-Surfacing TroubleshootingDetails/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–canprevent proper adhesion of the mat/灰尘或其它东西覆盖到预先已清理的路面–影响新旧路面的粘附力•Drying the stockpile–increases the likelihood of finessegregation/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–降低路面干燥速度28Micro-Surfacing TroubleshootingDetails/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 matsurface trapping water, causes long cure times andtenderness/结壳–干燥的风使路表变干，但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 highertemperature, keep stockpiles moist, and sweep/blow surfacejust ahead of lay-down equipment/预防性措施–将风视为高温，保持料堆润湿，摊铺前向路面鼓风29Micro-Surfacing TroubleshootingDetails/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 toshade from trees or buildings/增加/降低固化速率–树木或建筑产生的阴影会造成固化速率不一致•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，固化速率，沥青膜形成以及干燥速率30Micro-Surfacing TroubleshootingDetails/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–高湿度降低干燥速率•Stockpile drying and segregation–low humidity, even inthe absence of high temperatures, can cause stockpileproblems/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31Micro-Surfacing TroubleshootingDetails/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 propercoating of asphalt on aggregate/破坏部分固化的路面–不利于沥青在石料表面的裹附•Preventive measures–rolling or traffic consolidationprior 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 atonce/低温，荫凉及高湿度在同一时间发生32Micro-Surfacing TroubleshootingDetails/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 accountdifficult curing conditions, and emulsion reformulation isusually necessary/预防措施–混合料设计时需要将所有不利的养护条件都考虑进去，通常需要对乳化沥青配方做调整33Micro-Surfacing TroubleshootingDetails/微表处问题解决方法的具体内容•Emulsion Composition/乳化沥青组成–Asphalt/沥青•Inconsistent composition over time–effects emulsionstability, sieve, mix time, cure rate, adhesion, wear propertiesand rutting potential/沥青组成成份的变化–影响乳化沥青稳定性，过筛性能，拌合时间，固化速率，粘附性能，磨耗性能以及抗车辙性能•Preventive measures–know your crude source andmaintain good communication with the asphalt supplier/预防性措施–了解原油来源和性能，保持和沥青供应商的顺畅沟通34Micro-Surfacing TroubleshootingDetails/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 theemulsion/含有铁锈，沉淀物或者水溶性无机盐类（俗称硬水）-这些成分都会导致乳化沥青变得过于稳定或是失稳•Preventive measures–use potable (drinkable) water, test itperiodically and treat the water if necessary/预防性措施–使用自来水（适于饮用的水），对使用的水进行周期性的检测，必要时对水进行处理35Micro-Surfacing TroubleshootingDetails/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 andperformance changes or failures/化学成分的不一致性–引起乳液的稳定性和使用性能产生变化，或者项目失败•Contamination–reduces effectiveness/污染–降低乳化剂的活性•Preventive measures–ensure the quality of the product isconsistent 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“没有安排的的复配”36Micro-Surfacing TroubleshootingDetails/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 pHfluctuations leading to performance variations/浓度不一致–如果不进行控制，可能造成pH波动，进而造成性能差异•Preventive measures–accurate pH measurement usingcalibrated electronic devices (not pH paper) is critical/预防性措施–使用标定过的pH计准确测量pH值（不要使用pH试纸）37Micro-Surfacing TroubleshootingDetails/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, unevendistribution of polymer in the emulsion can cause changes inresidue properties (softening point or cold ductility) andrutting/胶乳的稳定性/结块–能够导致筛上剩余量的增加，以及胶乳在乳化沥青中不均匀分散，从而使得蒸发残留物性能（软化点或低温延度）以及车辙性能发生变化•Preventive measures–understand the product’s handlingproperties and stability/预防性措施–了解产品的正确的处理方法及稳定性能38Micro-Surfacing TroubleshootingDetails/微表处问题解决的具体内容•Emulsion Production/乳化沥青生产–Emulsifier solution production/皂液配置•Inaccurate measurement of emulsion componentquantities/计量不准确•Errors in material selection/材料选择错误•Inadequate agitation/搅拌不充分•Errors in sampling–emulsifier solution samples takenfor 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39Micro-Surfacing TroubleshootingDetails/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.)/皂液配置•Incorrect final solution temperature–can result in pooremulsion particle size/皂液温度不正确–会对乳化沥青的颗粒度产生发面影响40Micro-Surfacing TroubleshootingDetails/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.)/皂液配置•Preventive measures–have backup measuring devicesavailable, track material usage, make multiple quality checkson the solution prior to production, understand pH testequipment 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，记录材料用量；在生产前多次检测z皂液的质量；了解pH测试仪器的使用方法，在室温下检测pH值，保证皂液达到要求的乳化温度41Micro-Surfacing TroubleshootingDetails/微表处问题解决的具体内容•Emulsion Production (cont.)/乳化沥青生产–Mill operation/胶体磨的操作•Incorrect ratio of asphalt and solution –residue and viscositychanges/沥青和皂液进磨的比例不正确-从而导致乳化沥青固含量以及粘度的变化•Pump malfunction or clogged lines –may allow straightasphalt or emulsifier solution to go to storage/泵的故障或者管线的堵塞-可能使得沥青或皂液直接进入储罐42Micro-Surfacing TroubleshootingDetails/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 componentfluctuations during operation can produce poor emulsionquality (can occur over very short time periods)/操作不稳定–生产过程中温度或组分的波动导致生产的乳化沥青质量变差（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 ofsolution to asphalt line –may allow cooling of asphalt prior toentering the mill/不正确的构造对于连续式设备接入口或者额外的溶剂加入沥青管线–可能导致沥青在进入胶体磨前冷却43Micro-Surfacing TroubleshootingDetails/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 rotationalspeed, 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–造成乳化效率降低，颗粒度变大或者筛上剩余量增加•Insufficient back pressure–can allow cavitation in the millwhich causes poor particle size, sieve and curing problems/背压不足–能够在胶体磨中造成气穴现象，从而对乳化沥青颗粒度、筛上剩余量以及固化速率产生负面影响。