微表處乳化瀝青生產(chǎn)及施工問題解決方法_圖文

1、Troubleshooting in Micro-Surfacing Emulsion Production and Field Applications 微表處乳化瀝青生產(chǎn)及施工問題解決方法 呂紫劍 Laboratory Supervisor MeadWestvaco/美德維實偉克公司 Micro-Surfacing Troubleshooting /微表處問題的解決 What is the source of the problem?/什么是導(dǎo)致問題產(chǎn)生的原因？ 2 Micro-Surfacing Troubleshooting Motivation/解決微表處問題的動力 When EVE

2、RYONE cooperates in finding the cause of the problem, the amount of down time is minimized/當(dāng)我們每個人 齊心協(xié)力合作找出問題的原因時，停機的時間將被減到最小。 3 Micro-Surfacing Troubleshooting Objectives/微表處問題解決方案的目標(biāo) Method approach to problem solving/方法 解決問題的模式 Details/具體考慮細節(jié) Materials/施工材料 Equipment and Placement/施工設(shè)備和攤鋪方式 Enviro

3、nment/施工環(huán)境 Emulsion Production/乳化瀝青生產(chǎn) 4 Micro-surfacing Troubleshooting Method/微表處問題解決的方法 Logical Approach/邏輯上的思路 Weigh “real” data and “fuzzy” data differently/衡量區(qū)分“真實” 數(shù)據(jù)和“失真”數(shù)據(jù) Consider all possibilities/考慮所有的可能性 Dont avoid the real issue/不能回避真實的情況 Focus on the primary cause/注意力集中到主要原因上 Always ke

4、ep track of time frames/時刻保持時間紀錄 Use documentation and baselines/參考文獻記錄以及技術(shù)底限 There is no such thing as “Black Magic”/“萬靈魔法” Change one variable at a time/每次只檢測一個變量 5 Micro-surfacing Troubleshooting Method/微表處問題解決的方法 The big question is “What changed?”/關(guān)鍵問題“什么地方改變了嗎？” “We have been laying this stuff

5、 for 3 years, we havent changed anything, but suddenly it is not working”/“我們已經(jīng)利用現(xiàn)在的材料進 行微表處施工3年了，沒有改變過任何東西，為什么突然不行了呢？” 6 Micro-Surfacing Troubleshooting Method/微表處問題解決的方法 Start going down the list/從下面的列表開始 - Aggregate/骨料 - Materials handling/原材料處理 - Mineral filler/礦物填充料 - Contamination/污染 - Mix add

6、itives/拌合添加劑 - Surface preparation/表面處理 - Asphalt/瀝青 - Rain/降雨 - Water/水 - Humidity濕度 - Emulsifier/乳化劑 - Sun/shade/光照/蔭涼 - pH/酸堿度 - Wind/風(fēng) - Polymer/聚合物 - Temperature/溫度 - Calibration/計量 - Equipment malfunction/設(shè)備故障 7 Micro-surfacing Troubleshooting Details/微表處問題解決方法的具體內(nèi)容 Immediate during emulsion p

7、roduction or during the field application process/立即-在乳化瀝青生產(chǎn)或現(xiàn)場攤鋪過程產(chǎn)生的問題Long term failure that occurs weeks or months later/長期-問題出現(xiàn) 在幾個星期或幾個月以后 8 Micro-Surfacing Troubleshooting Details/微表處問題解決方法的具體內(nèi)容 Materials/材料 Emulsion (save for last/乳化瀝青（最后解釋） Aggregate/骨料 Changed aggregate source mineralogy ch

8、ange 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”/變換料源 石料巖性變化使和特定乳化瀝青/ 礦料及礦物填充料拌合時會導(dǎo)致缺乏拌合時間或者養(yǎng)護時間變 長（微表乳化瀝青不是“一個乳化瀝青適合所有系統(tǒng)”） 9 Micro-Surfacing Troubleshooting Details/微表處問題解決方法的具體內(nèi)容 Materials

9、 (cont./材料 Aggregate (cont./骨料 New crushing freshly crushed aggregate has a higher surface charge than weathered aggregate causing shorter mix times/新破碎石料 新破碎石料的表面電荷比堆放過的石料高， 造成可拌合時間變短 Different quarry face not all quarries are equal, and not all locations within a quarry are equal/不同料場 不是所有的料場 都是一樣

10、的，料場內(nèi)不同地方料源也可能不一樣 10 Micro-Surfacing Troubleshooting Details/微表處問題解決方法的具體內(nèi)容 Materials (cont./材料 Aggregate (cont./骨料 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/改 變粉料含量 粉料巖性

11、和含量在微表系統(tǒng)中起著最關(guān)鍵性的作 用，它能影響整個系統(tǒng)的短期和長期性能 Changing gradation can result mix time changes, in mat deformation, or bleeding of the asphalt in rut filling/改變骨料的 級配 能夠?qū)е掳韬蠒r間的改變，在車轍填補過程中再次出現(xiàn) 車轍或泛油 11 Micro-Surfacing Troubleshooting Details/微表處問題解決方法的具體內(nèi)容 Materials (cont./材料 Aggregate (cont./骨料 Fines/clay segr

12、egation causes performance variations within a single stockpile or load/細集料/粉料離析 造成同一堆 料或同一批料性能變化 Clay contamination variations in clay content within a single load caused by handling/粉料污染/在處理過程中造成同 一批骨料中粉料含量發(fā)生變化 12 Micro-Surfacing Troubleshooting Details/微表處問題解決方法的具體內(nèi)容 Materials (cont./材料 Aggregate

13、 (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 your baseline values are for each/預(yù)防性措施 熟悉料源（料場及 料場位置），定期檢測骨料的級配，砂當(dāng)量和亞甲藍，并確切 知道每項檢測所要求的指標(biāo)范圍 13 Micro-Surfacing Troubleshooting D

14、etails/微表處問題解決的具體內(nèi)容 Materials (cont./材料 Mineral filler/礦物填充料 Wrong mineral filler type use the designed type (cement, lime or alum/錯誤的礦物填充料的類型-使用設(shè)計的類型（水 泥，石灰或硫酸鋁） Wrong cement type using type IA (air entrained or type III (high early strength can lead to different results than type I/錯誤的水泥型號-使用IA型號水

15、泥（空氣引入）或者 III型水泥（較高早期強度）與I型號水泥相比造成不一樣的 結(jié)果 Affects mainly work time, curing rate and appearance of the mat/主要影響拌合時間，養(yǎng)護速率以及路面外觀 14 Micro-Surfacing Troubleshooting Details/微表處問題解決方法的具體內(nèi)容 Materials (cont./材料 Liquid additives/液體添加劑 Wrong chemical or concentration can effect work time and curing rate as w

16、ell as long term adhesion and wear properties 錯誤的化學(xué)性質(zhì)或濃度 會影響拌合時間，養(yǎng)護速率以及長期 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/含有鐵銹，沉淀物或者水溶 性的無機鹽（硬水）- 會影響拌合時間及固化速率 15 Micro-Surfacing Troubleshooting Details/微表處問題解決的具體內(nèi)容 Equipment and Placemen

17、t/設(shè)備和攤鋪 Micro-Surfacing machine/微表攤鋪車 Incorrect calibration changes component ratios resulting in inconsistent results or long term performance failures/錯誤 的標(biāo)定 導(dǎo)致各種組分比例發(fā)生變化與設(shè)計結(jié)果不一致或者長 期路用性能變差 Clogged mineral filler chute not easily noticed but can have significant effects/礦物填充料進料管道堵塞 比較不容易 發(fā)現(xiàn)但是有非常顯著

18、的影響 Worn parts causes calibration to change over time/磨損部件 隨著時間的過去會引起標(biāo)定結(jié)果偏移 16 Micro-Surfacing Troubleshooting Details微表處問題解決的具體內(nèi)容 Equipment and Placement (cont./設(shè)備和攤鋪 Micro-Surfacing machine (cont./微表攤鋪車 Clogged lines or pumps produces changes in mix composition that are difficult to see/管道或泵堵塞 造成難

19、以 覺察的出料組分變化 Contaminated tanks introduces a component that was not designed into the system/儲罐污染 引入設(shè)計中未涉及組分 17 Micro-Surfacing Troubleshooting Details/微表處問題解決方法的具體內(nèi)容 Equipment and Placement (cont./設(shè)備和攤鋪 Micro-Surfacing machine (cont./微表攤鋪車 Incorrect pug mill mixing action pug mill type (single auger

20、 vs twin auger or malfunction causes incomplete mixing or foaming and splashing/拌合箱內(nèi)不正常拌合行為 拌合箱類 型（單軸 vs 雙軸）或者機械故障導(dǎo)致拌合不充分，起泡或跑 漿 Lay-down box augers, seals or dead spots causes lack of control in the mix placement or drag marks/攤鋪箱攪拌軸，刮板或死角 造成對混合料缺乏控制或 有拖痕 18 Micro-Surfacing Troubleshooting Details/

21、微表處問題解決的具體內(nèi)容 Equipment and Placement (cont./設(shè)備和攤鋪 Micro-Surfacing machine (cont./微表攤鋪車 Preventive measures periodic recalibration, scheduled preventive maintenance, cleaning the equipment, and use of the right equipment designed specifically for micro-surfacing/ 預(yù)防性措施 周期性再次標(biāo)定，制定預(yù)防性養(yǎng)護時間表，注意 設(shè)備的清潔和選用正

22、確的微表專用攤鋪設(shè)備 19 Micro-Surfacing Troubleshooting Details/微表處問題解決方法的具體內(nèi)容 Equipment and Placement (cont./設(shè)備和攤鋪 Material transport and storage/材料運輸和儲存 Over-pumping of emulsion pumps with shearing surfaces (gear pumps for example stress emulsions causing build-up of sieve/過度甭送乳化瀝青 當(dāng)用具有剪切的功能（如齒輪 泵）的泵泵送乳化瀝青，

23、會造成乳化瀝青粒徑變粗 Stockpile drying and wind exposure as fines dry and the stockpile is worked, the fines migrate to the bottom/料堆干燥 及暴露在風(fēng)中 當(dāng)細集料變干后，繼續(xù)堆放時，細料會向底部 遷移 20 Micro-Surfacing Troubleshooting Details/微表處問題解決方法的具體內(nèi)容 Equipment and Placement (cont./設(shè)備和攤鋪 Material transport and storage (cont./材料運輸和儲存 Mi

24、neral filler exposed to moisture cement that is partially hardened and then broken up does not perform the same as dry cement/礦物填充料受潮 水泥部分硬化后再破碎使用，和 未吸過水的水泥的效果完全不一樣 Stockpile contamination As little as 0.5% added clay in one loader bucket can have catastrophic results/堆料受污染 引入微少哪怕只有0.5%的粘土，都會產(chǎn)生災(zāi)難性的結(jié)

25、果 21 Micro-Surfacing Troubleshooting Details/微表處問題解決的具體內(nèi)容 Equipment and Placement (cont./設(shè)備和攤鋪 Material transport and storage (cont./材料運輸和儲存 Preventive measures minimize pumping of emulsion, keep stockpiles moist (>2%, keep mineral filler out of the weather, educate loader and screening plant ope

26、rators about stockpile placement and management/預(yù)防性措施 盡量減少乳化瀝青 的泵送次數(shù)，保證料堆的含水量（>2%）, 避免礦物填充料暴 露在空氣中，培訓(xùn)鏟車手和石料篩分操作人員關(guān)于料堆的堆放 和管理知識 22 Micro-Surfacing Troubleshooting Details/微表處問題解決的具體內(nèi)容 Equipment and Placement (cont./設(shè)備和攤鋪 Placement/攤鋪 Overworking the mix working the mix beyond the point where is sh

27、ould begin to set produces a tender mat/過度拌合 過度拌合超過應(yīng)該硬結(jié)的時間點從而導(dǎo)致攤鋪后路面無強度 Mix is too fast (false slurry mix breaks before final placement which strips coalescing asphalt film from aggregate, cures slowly/拌合太快（假稀漿） 混合料在攤鋪 前破乳，造成破乳后的瀝青膜剝落，而且強度上升慢 23 Micro-Surfacing Troubleshooting Details/微表處問題解決方法的具體內(nèi)容

28、 Equipment and Placement (cont./設(shè)備和攤鋪 Placement (cont./攤鋪 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/加水延長拌 合時間 可能導(dǎo)致跑漿，造成骨料和乳化瀝青之間的離席，從 而影響路面紋理 Surface preparation mat laid on top of dir

29、ty surfaces, loose objects, or over surfaces that provide poor adhesion/攤鋪前路 面處理 攤鋪在臟路面，松散物體或粘附性很差路表 24 Micro-Surfacing Troubleshooting Details/微表處問題解決方法的具體內(nèi)容 Equipment and Placement (cont./設(shè)備和攤鋪 Placement (cont./攤鋪 Preventive measures in place of additional water, use chemical retarder additives or

30、 reformulate emulsion to improve work time, roughen smooth surfaces such as pavement markings, and clean oil spots/預(yù)防性措施 用化學(xué) 緩破劑或調(diào)整乳化瀝青配方來替代外加水延長拌合時間，打毛 光滑路面就像路面的標(biāo)記，清理油斑 25 Micro-Surfacing Troubleshooting Details/微表處問題解決方法的具體內(nèi)容 Environment/環(huán)境 Temperature/溫度 Sudden temperature swings without a corres

31、ponding emulsion reformulation/環(huán)境溫度突然波動 事先沒有相應(yīng)的乳 化瀝青配方調(diào)整措施 Freeze before total cure results can range from raveling to total failure/在強度完全前結(jié)冰 造成裂縫或整體破壞 Emulsion temp too high can cause the work time to be reduced/乳化瀝青溫度過高 造成拌合時間變短 26 Micro-Surfacing Troubleshooting Details/微表處問題解決方法的具體內(nèi)容 Environment

32、 (cont./環(huán)境 Temperature (cont./溫度 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/預(yù)防性 措施 密切關(guān)注環(huán)境溫度，預(yù)先計劃，提供乳化瀝青生產(chǎn)商足 夠的時間生產(chǎn)和運輸配方正確的，溫度正確的乳化瀝青 27 Micro-Surfacing Troubleshooting Deta

33、ils/微表處問題解決的具體內(nèi)容 Environment (cont./環(huán)境 Wind/風(fēng) Dust or other material blown onto prepared surface can prevent proper adhesion of the mat/灰塵或其它東西覆蓋到預(yù) 先已清理的路面 影響新舊路面的粘附力 Drying the stockpile increases the likelihood of fines segregation/料堆干燥 增加細集料離析的可能性 Lack of wind can decrease drying rate/風(fēng)力太小 降低路面 干

34、燥速度 28 Micro-Surfacing Troubleshooting Details/微表處問題解決的具體內(nèi)容 Environment (cont./環(huán)境 Wind (cont./風(fēng) Skinning of the mat dry wind flash dries the uncured mat surface trapping water, causes long cure times and tenderness/結(jié)殼 干燥的風(fēng)使路表變干，但大部分水分無法揮 發(fā)，造成養(yǎng)護時間延長，路面變軟 Preventive measures think of wind as equivalen

35、t to higher temperature, keep stockpiles moist, and sweep/blow surface just ahead of lay-down equipment/預(yù)防性措施 將風(fēng)視為高 溫，保持料堆潤濕，攤鋪前向路面鼓風(fēng) 29 Micro-Surfacing Troubleshooting Details/微表處問題解決的具體內(nèi)容 Environment (cont./環(huán)境 Sun/shade/光照/蔭涼 Increase/decrease in curing rate may be spotty due to shade from trees o

36、r buildings/增加/降低固化速率 樹木或建筑 產(chǎn)生的陰影會造成固化速率不一致 Surface temperature large factor in work time, curing rate, asphalt film formation, and drying rate/路面溫度 大大影響拌 合時間，固化速率，瀝青膜形成以及干燥速率 30 Micro-Surfacing Troubleshooting Details/微表處問題解決的具體內(nèi)容 Environment (cont./環(huán)境 Humidity/濕度 Drying rate high humidity slows dr

37、ying rate/干燥速率 高濕 度降低干燥速率 Stockpile drying and segregation low humidity, even in the absence of high temperatures, can cause stockpile problems/料堆干燥和離析 濕度太低時，即使環(huán)境溫度不高也 會導(dǎo)致料堆問題 31 Micro-Surfacing Troubleshooting Details/微表處問題解決的具體內(nèi)容 Environment (cont./環(huán)境 Rain/雨水 Disturbs partially cured mat does not

38、allow proper coating of asphalt on aggregate/破壞部分固化的路面 不利于瀝青在 石料表面的裹附 Preventive measures rolling or traffic consolidation prior to rain can help/預(yù)防性措施 下雨前事先壓路機壓實或開放交通 加固 Night work/夜間施工 Effects of low temp, shade and high humidity all at once/ 低溫，蔭涼及高濕度在同一時間發(fā)生 32 Micro-Surfacing Troubleshooting Det

39、ails/微表處問題解決方法的具體內(nèi)容 Environment (cont./環(huán)境 Night work (cont./夜間施工 Preventive measures mix design must take into account difficult curing conditions, and emulsion reformulation is usually necessary/預(yù)防措施 混合料設(shè)計時需要將所有不利的 養(yǎng)護條件都考慮進去，通常需要對乳化瀝青配方做調(diào)整 33 Micro-Surfacing Troubleshooting Details/微表處問題解決方法的具體內(nèi)容 E

40、mulsion Composition/乳化瀝青組成 Asphalt/瀝青 Inconsistent composition over time effects emulsion stability, sieve, mix time, cure rate, adhesion, wear properties and rutting potential/瀝青組成成份的變化 影響乳化瀝青穩(wěn)定 性，過篩性能，拌合時間，固化速率，粘附性能，磨耗性能以 及抗車轍性能 Preventive measures know your crude source and maintain good communic

41、ation with the asphalt supplier/預(yù)防 性措施 了解原油來源和性能，保持和瀝青供應(yīng)商的順暢溝通 34 Micro-Surfacing Troubleshooting Details/微表處問題解決方法的具體內(nèi)容 Emulsion Composition (cont./乳化瀝青組成 Water/水 Contains rust, sediment, or dissolved salts (hard water these components will act to either stabilize or destabilize the emulsion/含有鐵銹，沉

42、淀物或者水溶性無機鹽類（俗稱硬 水）-這些成分都會導(dǎo)致乳化瀝青變得過于穩(wěn)定或是失穩(wěn) Preventive measures use potable (drinkable water, test it periodically and treat the water if necessary/預(yù)防性措施 使 用 自來水（適于飲用的水），對使用的水進行周期性的檢測， 必要時對水進行處理 35 Micro-Surfacing Troubleshooting Details/微表處問題解決的具體內(nèi)容 Emulsion Composition (cont./乳化瀝青組成 Emulsifier/乳化劑 I

43、nconsistent chemical composition causes stability and performance changes or failures/化學(xué)成分的不一致性 引起 乳液的穩(wěn)定性和使用性能產(chǎn)生變化，或者項目失敗 Contamination reduces effectiveness/污染 降低乳化劑的 活性 Preventive measures ensure the quality of the product is consistent over time and watch out for “unscheduled blends”/ 預(yù)防性措施 確保乳化劑

44、的質(zhì)量是一致的，防止“沒有安排的 的復(fù)配” 36 Micro-Surfacing Troubleshooting Details/微表處問題解決的具體內(nèi)容 Emulsion Composition (cont./乳化瀝青組成 Acid/酸 Inconsistent concentration if not controlled, causes pH fluctuations leading to performance variations/濃度不一致 如 果不進行控制，可能造成pH波動，進而造成性能差異 Preventive measures accurate pH measurement

45、using calibrated electronic devices (not pH paper is critical/預(yù)防性 措施 使用標(biāo)定過的pH計準確測量pH值（不要使用pH試紙） 37 Micro-Surfacing Troubleshooting Details/微表處問題解決的具體內(nèi)容 Emulsion Composition (cont./乳化瀝青組成 Latex/膠乳 Latex stability/coagulum can cause sieve, uneven distribution of polymer in the emulsion can cause chang

46、es in residue properties (softening point or cold ductility and rutting/膠乳的穩(wěn)定性/結(jié)塊 能夠?qū)е潞Y上剩余量的增加，以及 膠乳在乳化瀝青中不均勻分散，從而使得蒸發(fā)殘留物性能（軟 化點或低溫延度）以及車轍性能發(fā)生變化 Preventive measures understand the products handling properties and stability/預(yù)防性措施 了解產(chǎn)品的正確的處理方 法及穩(wěn)定性能 38 Micro-Surfacing Troubleshooting Details/微表處問題解決的具

47、體內(nèi)容 Emulsion Production/乳化瀝青生產(chǎn) Emulsifier solution production/皂液配置 Inaccurate measurement of emulsion component quantities/ 計量不準確 Errors in material selection/材料選擇錯誤 Inadequate agitation/攪拌不充分 Errors in sampling emulsifier solution samples taken for testing prior to complete reaction with acid/取樣錯誤

48、取樣測 試的皂液還沒有和酸反應(yīng)完全 Errors in pH testing/pH測試有誤 39 Micro-Surfacing Troubleshooting Details/微表處問題解決的具體內(nèi)容 Emulsion Production (cont./乳化瀝青生產(chǎn) Emulsifier solution production (cont./皂液配置 Incorrect final solution temperature can result in poor emulsion particle size/皂液溫度不正確 會對乳化瀝青的顆粒 度產(chǎn)生發(fā)面影響 40 Micro-Surfaci

49、ng Troubleshooting Details/微表處問題解決的具體內(nèi)容 Emulsion Production (cont./乳化瀝青生產(chǎn) Emulsifier solution production (cont./皂液配置 Preventive measures have backup measuring devices available, track material usage, make multiple quality checks on the solution prior to production, understand pH test equipment opera

50、tion, make pH measurements at room temp, hit target production temps/預(yù)防性措施 預(yù)先準備備用的測試 儀器，記錄材料用量；在生產(chǎn)前多次檢測z皂液的質(zhì)量；了解 pH測試儀器的使用方法，在室溫下檢測pH值，保證皂液達到 要求的乳化溫度 41 Micro-Surfacing Troubleshooting Details/微表處問題解決的具體內(nèi)容 Emulsion Production (cont./乳化瀝青生產(chǎn) Mill operation/膠體磨的操作 Incorrect ratio of asphalt and solutio

51、n residue and viscosity changes/瀝青和皂液進磨的比例不正確-從而導(dǎo)致乳化瀝青固含 量以及粘度的變化 Pump malfunction or clogged lines may allow straight asphalt or emulsifier solution to go to storage/泵的故障或者管 線的堵塞-可能使得瀝青或皂液直接進入儲罐 42 Micro-Surfacing Troubleshooting Details/微表處問題解決的具體內(nèi)容 Emulsion Production (cont./乳化瀝青生產(chǎn) Mill operation

52、 (cont./膠體磨的操作 Unsteady operation temperature or component fluctuations during operation can produce poor emulsion quality (can occur over very short time periods/操作不穩(wěn)定 生產(chǎn)過程中溫度或組分的波動導(dǎo)致生產(chǎn)的乳化瀝青質(zhì)量變差 （在很短的時間內(nèi)的波動就可造成這種結(jié)果） Incorrect configuration for in-line injection or addition of solution to asphalt line may allow cooling of asphalt prior to entering the mill/不正確的構(gòu)造對于連續(xù)式設(shè)備接入口或者額外 的溶劑加入瀝青管線 可能導(dǎo)致瀝青在進入膠體