cff gmbh & co. kg your supplier of native cellulose fibers cff‘s products and application in...
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CFF GmbH & Co. KG
Your supplier of native cellulose fibers
CFF‘s products and
application in SMA
CFF GmbH & Co. KG
CFF GmbH & Co. KGCFF GmbH & Co. KG
• CFF
• SMA
• GENICEL Modification
CFF GmbH & Co. KGLocation in Gehren / Thuringia
CFF GmbH & Co. KG
CFF GmbH & Co. KG
Factory in Gehren/Thuringia
CFF GmbH & Co. KG
Founded 1977 Employees 80 Production capacity approx. 42.000 tons
(> 17.000 tons for TOPCEL) Export rate > 70 % Certified to ISO 9001
SMA Stone Matrix Asphalt
Basics
Modification of bitumen
CFF GmbH & Co. KG
HighwayA 9,Situation in year
1994
Transportation
CFF GmbH & Co. KG
Today: permanent traffic jams
CFF GmbH & Co. KG
SMA – Stone Matrix Asphalt
Stone Matrix Asphalt :– aggregate mix with a high content of large
aggregates– only crushed aggregates– Mainly Modified bitumen – stabilising additives for the prevention of bitumen
drainage during storage, transport, laying down.
CFF GmbH & Co. KG
CFF GmbH & Co. KG Comparison of mineral structure
Stone Mastic Asphalt / Asphalt Concrete
Coarse aggregate 73 - 80 weight.-% 55 - 65 weight.-%> 2mm
Filler/Sand Content 20 - 27 weight.-% 35 - 45 weight.-%< 2mm
Bitumen Content > 6,5 weight.-% 5,9 - 7,2 weight.-%Air Void Content < 6 Vol.-% < 7 Vol.-%
SMA 0/11 AC 0/11
characteristicscharacteristics propertiesproperties
High content of chippings
Bitumen: modified Bitumen
thick bitumen-/ mortarcoatings
stabilising additivs (TECHNOCEL /
TOPCEL)
Stone skeleton - High stability (temperature
independent)
Supporting the stability
Better aging behavior
Prevention of the bitumen drainage during storage, transport, laying down
CFF GmbH & Co. KG
CFF GmbH & Co. KG
Asphalt Concrete SMA
High resistance to permanent deformation
characteristics of SMA – under performance conditions
High resistance to attrition / wear
Not sensitive to low temperature cracking and mechanical stresses
Coarse grained surface texture
Longer lifetime
CFF GmbH & Co. KG
Aggregates
aggregates with high polishing resistance heavy duty traffic !!
PSV min. 50
cubic aggregate shape not flaky, not elongated!
Relation crushed sand / natural sand
1 : 0
CFF GmbH & Co. KG
Binder / Bitumen
bitumen (straight run) DIN EN 12591
Bitumen 50 / 70
For heavy duty traffic, bridges : Polymer Modified Bitumen PmB 45 or GENICEL modified Bitumen
CFF GmbH & Co. KG
Stabilising additivs
Prevention of the bitumen drainage during storage, transport, laying down:
Materials:Cellulose granules / pelletsTECHNOCEL 1004-G - granulesTOPCEL - pelletsGENICEL - 2-component-pellets (cellulose +
bitumenmodifier)
CFF GmbH & Co. KG
CFF GmbH & Co. KG
Function of stabilizing additives in asphalt
- TECHNOCEL ® and TOPCEL ®
used primarily as a bitumen carrier to increasethe thickness of binder coating.
- TECHNOCEL ® and TOPCEL ®
designed to stabilize the homogenity of asphaltand to avoid the drainage of the binder fromthe mineral aggregate duringproduction, storage, transport and lay down.
Mix design
grading SMA 0/11S
2/5 1
5/8 2
8/11 4
parts
SMA 0/8S
2
5,5
parts
SMA 0/8
2,5
4,5
parts
CFF GmbH & Co. KG
SMA 0/11 S
AC 0/11
mesh density Square holes density [mm]
passin
g a
sie
ve [
M.-
%]
rem
ain
ing
on
sie
ve [
M.-
%]
CFF GmbH & Co. KG
CFF GmbH & Co. KG
Splittmastixasphalt
Bezeichnung SMA 16
S SMA 11
S SMA 8
S SMA 5
S SMA 8
N SMA 5
N
Baustoffe
Gesteinskörnungen (Lieferkörnung)
Widerstand gegen Zertrümmerung SZ SZ18 (LA20) SZ18 (LA20) SZ18 (LA20) SZ18 (LA20) SZ18 (LA20) SZ18 (LA20)
Widerstand gegen Polieren PSV PSV53 PSV53 PSV53 PSV53 PSV50 PSV44 res. Mindest-Fließkoeffizient der Korngruppen 0/2
s 38 35 35 35 30 30
Bindemittel, Art und Sorte PmB 45;
PmB 25; 50/70
PmB 45; (PmB 25)
PmB 45; (PmB 25)
(PmB 45); PmB65; 50/70
50/70; 70/100; PmB 65
70/100; 50/70
Draft for new European standard: 2007
CFF GmbH & Co. KG
Zusammensetzung Asphaltmischgut
Gesteinskörnungen
Siebdurchgang bei 16 mm M.-% 90 bis 100 11 mm M.-% 65 bis 80 90 bis 100 8 mm M.-% 55 bis 60 50 bis 60 90 bis 100 90 bis 100 5 mm M.-% 35 bis 45 35 bis 55 90 bis 100 40 bis 70 90 bis 100 2 mm M.-% 20 bis 30 20 bis 30 20 bis 30 30 bis 40 20 bis 30 30 bis 40
0,125 mm M.-% 9 bis 14 9 bis 14 9 bis 14 9 bis 17 9 bis 16 9 bis 17 0,063 mm M.-% 8 bis 12 8 bis 12 8 bis 12 7 bis 12 7 bis 12 7 bis 12
Bindemittelgehalt Bmin Bmin 6,4 Bmin 6,8 Bmin 7,2 Bmin 7,4 Bmin 7,2 Bmin 7,4
Bindemittelträger M.-% 0,3 – 1,5 0,3 –1,5 0,3 – 1,5 0,3 – 1,5 0,3 – 1,5 0,3 – 1,5
Mischguteigenschaften
minimaler Hohlraumgehalt Vmin Vmin 3,0 Vmin 3,0 Vmin 3,0 Vmin 2,0 Vmin 2,0 Vmin 2,0
maximaler Hohlraumgehalt Vmax Vmax 4,0 Vmax 4,0 Vmax 4,0 Vmax 4,0 Vmax 4,0 Vmax 4,0
maximaler Hohlraumausfüllungsgrad VFBmax VFBmax80 VFBmax83 VFBmax83 VFBmax83 VFBmax86 VFBmax86
proportionale Spurrinnentiefe PRDLuft PRDLuftNR PRDLuftNR PRDLuftNR
Splittmastixasphalt
Bezeichnung SMA 16
S SMA 11
S SMA 8
S SMA 5
S SMA 8
N SMA 5
N
Stability tests
• Marshalltest (Stability and flow) not suitable!
• Wheel Tracking Test (WTT) – „Bestimmung der Spurtiefe “ nach TP A-StB
suitable!
• Dynamic compression test (Druckschwellversuch) – „Bestimmung des Verformungs- verhaltens von Walzasphalten bei Wärme“ nach TP A-StB
suitable!
CFF GmbH & Co. KG
WTT - Wheel Tracking Test
CFF GmbH & Co. KG
WTT - Wheel Tracking Test
CFF GmbH & Co. KG
WTT - Wheel Tracking Test
Failed samples
CFF GmbH & Co. KG
WTT - Wheel Tracking Test
Failed samples
CFF GmbH & Co. KG
“Binder Drainage Test” ( Schellenberg / v.d. Weppen)
Give 1000 bis 1100 g asphalt under production conditions (temperature) into a 800 ml glass beaker
Store the covered beaker for 60 +/- 1 min in a preheated oven (temperature 170°C +/- 1°C)
Directly after removal – turn the glass beaker from bottom to the top
Weigh the beaker incl. the remaining bitumen with a precision of 0,01 weight %
• more remaining bitumen/asphalt – more segregation!
CFF GmbH & Co. KG
CFF GmbH & Co. KG
Left side: SMA with 0,3% TECHNOCEL® / TOPCEL ®
Right side: SMA without stabilizing additives
The binder drain down test shows
whether a stabilizing additive can prevent
draining down of the binder and the asphalt mortar
from the mineral aggregates.
A remainder of approx. 0.1 - 0.2 is considered as indicative value.
0 0, 1 0, 2 0,3 0,4 0,5 Fiber adding in weight-%
1,8
1,6
1,4
1,2
1,0
0, 8
0, 6
0, 4
0,
2 0
Bin
der d
rain
ag
e in
weig
ht-%
0,05 0,15 0,3 0,45
2,0
0,3
0,08 0,05
Amount of bitumen of an SMA 0/11dependend on the fiber content(Cellulose)
Amount of bitumen of an SMA 0/11dependend on the fiber content(Cellulose)
CFF GmbH & Co. KG
Manufacturing process of SMA:
We recommend the following procedure by using
TECHNOCEL, TOPCEL and/or GENICEL
(DAV – German Asphalt Association e.V., December 2000):
......
5 - 15 sec.
approx. 20 sec.
5 - 10 sec.
Mineral
Aggregates
Mineral
Aggregates
and Additives
Bitumen
Post mixing
<------’dry premixing period’---------->I<--------’wet mixing period’------------>
CFF GmbH & Co. KG
- manually or
- automatic dosing systems
Dosage facilities
SMA paving
CFF GmbH & Co. KG
CFF GmbH & Co. KG
SMA paving
CFF GmbH & Co. KG
Skid resistance Stone Mastic Asphalt
To ensure the required grip, it is recommended to spread:
- 1-2 kg/m² dedusted high quality chippings 2/5mm or
- 0,5 - 1 kg/m² crushed sand-chippings mix 1/3mm
The blinding material may be spread with a disk scatterers fitted to a roller. Spread the blinding material on the hot surface course, but not before the second roller pass.
CFF GmbH & Co. KG
Homogeneous gritting of SMA with a disk scatterer fitted to a roller
directionSpreading of crushed
stones
CFF GmbH & Co. KG
Gritting measures
1-2 kg/m² dedusted high quality chippings 2/5mm or0,5 - 1 kg/m² crushedsand-chippings mix 1/3mm
SMA - possible problems
Water comes out of the surface after drying (rain) – possible glace ice during wintertime
Bad skid resistance
Segregation - areas with high bitumen content on the surface (“bitumen bleeding“)
CFF GmbH & Co. KG
bitumen content too high
CFF GmbH & Co. KG
Compaction, which roller?
CFF GmbH & Co. KG
Uneven distribution of bitumen in the mix
CFF GmbH & Co. KG
Bad homogenity of the asphalt mixture
CFF GmbH & Co. KG
Bitumen / Binder
Modification of Bitumen / Asphalt
CFF GmbH & Co. KG
Additivs for modifcation
CFF GmbH & Co. KG
Modification of domestic bitumen by using
GENICEL
CFF GmbH & Co. KG
Changing the main characteristics of
standard bitumen
Ring and ball Penetration
CFF GmbH & Co. KG
Main trends for changing the RaB,
Pen by using GENICEL
45
81,5 73
44
0
20
40
60
80
100
Changing the main characteristics of bitumen by
using GENICEL
– the Ring and Ball point will grow in the range between 35 and 45 °C
– The penetration point will degrease in the range between 25 and 35 1/10mm
– The breaking point (Fraaß) will stay nearly constant in the range of the original bitumen
CFF GmbH & Co. KG
GENICEL
Adhesion to minerals – The adhesion to critical minerals will be
improved
CFF GmbH & Co. KG
Adhesion to minerals
Straight run bitumen GENICEL modified
CFF GmbH & Co. KG
Workability – reduce the mixing temperatures up to
approx. 160°C – the asphalt mix has a very high
compactability Environmental pollution
– reducing the emission of CO2 and other air pollutants
– reducing the use of energy – reduction is up to 20% is possible
GENICEL
CFF GmbH & Co. KG
(1) Bitumen 70 / 100(2) Bitumen PmB 45(3) GENICEL mod. Bitumen
12
3
CFF GmbH & Co. KG
Wheel Tracking Test with different kinds of bitumen [SMA 0/ 8S, chippings 75% , bitumen 7% ]
0
0,5
1
1,5
2
2,5
3
3,5
4
4,5
5
0
10
00
20
00
30
00
40
00
50
00
60
00
70
00
80
00
90
00
10
00
0
11
00
0
12
00
0
13
00
0
14
00
0
15
00
0
16
00
0
17
00
0
18
00
0
19
00
0
20
00
0
amount of overrollings
Ru
t d
epth
in m
m
resistance against rutting – the rut depth measured in the wheel
tracking test device will be minimised – The reduction rate compared with standard
bitumen is minimum 50% Viscosity
– the viscosity can be compared with bitumen 70/100
GENICEL
CFF GmbH & Co. KG
121 134 145
GENICEL
Bitumen 50/70
PmB 45A
CFF GmbH & Co. KG
SMA 0/11 S
2,0%
2,5%
3,0%
3,5%
4,0%
4,5%
5,0%
95 105 115 125 135 145 155 165
Compactiontemperatur [°C]
vo
id c
on
ten
t M
PK
[%
]
CFF GmbH & Co. KG
TOPCEL Pellets
TECHNOCEL 1004-GGranules
CFF‘s products for road construction:
CFF GmbH & Co. KG
GENICEL 2-Component-Pellets (TECHNOCEL-Cellulose fibers + SASOBIT-Bitumen-Modifier)
CFF‘s products for road construction:
CFF GmbH & Co. KG
Fields of application:
l Stone Mastic Asphalt (SMA)
l Open-Porous Asphalt (OPA) or drain asphalt
l special asphalt concrete mix designs
l “ Heavy duty binder courses ”
CFF GmbH & Co. KG
THANK YOU FOR YOUR ATTENTION !
CFF GmbH & Co. KG
CFF GmbH & Co. KG
Arnstädter Str. 2
D – 98708 Gehren
Tel. +49 36783 882-265
Fax +49 36783 882-252
Email: s.schulz@cff.de
Home-Page: www.cff.de
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