Engineering Road

Note 14

Guide to Spreading
Aggregate in a Seal
September 2018

Printed copies are uncontrolled unless marked otherwise. D18#615318

September 2018
Guide to Spreading Aggregate in a Seal – September 2018

Contents
1 INTRODUCTION ................................................................................................................... 3
2 BACKGROUND .................................................................................................................... 3
3 DESIGN AGGREGATE SPREAD RATE ............................................................................... 3
4 CALCULATION OF DESIGN AGGREGATE SPREAD RATE .............................................. 5
4.1 Example Calculation .............................................................................................................. 6
5 AGGREGATE SPREAD RATE – DOUBLE/DOUBLE SEALS .............................................. 6
6 APPLICATION OF AGGREGATE ......................................................................................... 6
7 USE OF THE PHOTO GUIDE ............................................................................................... 7
8 REFERENCES AND RELATED DOCUMENTS .................................................................. 25

Document Control
Owner Manager Materials Engineering

Custodian Bituminous Products Consultant

Document Number D18#615318

Issue Date September 2018

Review Frequency As required

Amendments
Revision Section /
Revision Date Description of Key Changes
Number Page No.

September
0 New Document
2018

Author Steve Halligan

Reviewer/Approval Les Marchant

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Guide to Spreading Aggregate in a Seal – September 2018

1 INTRODUCTION
This Engineering Road Note provides guidance to assist practitioners in achieving good outcomes
when spreading aggregate in a sprayed seal. It contains background information on the
importance of the aggregate spread rate as well as photo references for comparison in the field.

2 BACKGROUND
Sprayed seals consist of aggregate spread over a layer of bituminous binder. The aggregate
component provides resistance to abrasion and a textured surface for skid resistance.

Aggregate is spread according to a design aggregate spread rate. The design aggregate spread
rate is influenced by the average least dimension (ALD) of the aggregate and is commonly
expressed in m2/m3. A rate of 100m2/m3 corresponds to a 1m3 volume of aggregate being evenly
spread over an area of 100m2. A greater number for the rate (e.g. 120 m2/m3) indicates a lighter
coverage as a given volume of aggregate is spread over a larger area. Conversely, a lower rate
(e.g. 80 m2/m3) indicates a heavier coverage as the same amount of aggregate is spread over a
smaller area.

The average least dimension (ALD) is defined in the Austroads Glossary of Terms (AP-C87-15) as
‘the average height of the aggregate particles when they are spread as a single layer with their
least dimensions vertical’. The least dimension is the smallest dimension of a particle when placed
on a horizontal surface. An aggregate particle is most stable in a position where its least dimension
is vertical. A schematic of this principle is provided in Section 1.6 of the Austroads Technical
Report, Update of the Austroads Sprayed Seal Design Method (APT68-06).

3 DESIGN AGGREGATE SPREAD RATE

Aggregate particles need to be spread at a rate that allows the particles to move during rolling to
achieve an optimal alignment. This is achieved by spreading at the design aggregate spread rate
where aggregate particles should form a continuous, partly interlocking mosaic (Figure 2). The
interlocking mosaic generally provides resistance to the shearing and plucking effect of traffic.

To achieve this interlocking mosaic, the aggregate is rolled shortly after having been spread over a
bituminous binder. During this process, the aggregate particles rearrange to a more stable position
where the least dimension is aligned towards vertical. This change can be observed in Figure 1
and Figure 2 which show the orientation of the aggregate particles before and after rolling.

Prior to rolling, the distribution of aggregate particles has large spaces of exposed binder as
observed in Figure 1. This is necessary to give room for the particles to reorientate. After rolling
these spaces close up as the particles settle into a more stable position as shown in Figure 2.

This reorientation of the aggregate particles continues before and after opening to unrestricted
traffic. Where the correct aggregate spread rate is achieved nearly all aggregate will reorientate
such that the least dimension is near vertical. The extent and rate of reorientation is affected by the
volume of traffic, especially the number of heavy vehicles. Thus, the spaces observed in Figure 2
are expected to further reduce after exposure to traffic.

It is essential that aggregate is spread at the design aggregate spread rate as this affects the void
space available for the binder to fill and hence the depth of binder rise. If the design aggregate
spread rate is not achieved, binder applied at the design binder rate will be incorrect and this will
have an impact on the performance of the seal.

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Guide to Spreading Aggregate in a Seal – September 2018

Figure 1 Aggregate as spread before rolling

Figure 2 Aggregate after rolling

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If aggregate is spread too heavily, there is insufficient space for reorientation and the particles are
unable to settle to their most stable position. As the inter-aggregate void space is reduced, binder
may rise above a depth of two thirds up the aggregate potentially leading to flushing and reduced
texture.

If the aggregate is spread too lightly, the aggregate particles will be unable to form a continuous
interlocked mosaic. Due to the greater void space between the aggregate particles, the binder rise
will be lower resulting in a potentially reduced seal life.

4 CALCULATION OF DESIGN AGGREGATE SPREAD RATE

The design aggregate spread rate is calculated based on the ALD. Aggregate spread rates for
different types of sprayed seals are summarised in Table 1. An example calculation is also
included.

Table 1 Typical Aggregate spread rate for various sprayed seals

Typical Aggregate
Application
Spread Rate

Class 170, Class 320 Bitumen

Single/single initial seal 900/ALD
Single/single reseal 900/ALD
Double/double seal first application 950/ALD
Double/double seal second application of 1050/ALD – 1100/ALD
7mm aggregate (Note 1)
PMB Seals
Aggregate Retention 900/ALD
High Stress Seal 900/ALD
Strain Alleviating Membrane (SAM) 900/ALD
Strain Alleviating Membrane Interlayer (SAMI) 1000/ALD
16mm stone (Note 2) 1275/ALD
20mm stone to achieve nominal aggregate spread rate 1550/ALD
of 110m2/m3 (Note 2)
Note 1: If the ALD of 7mm stone is not known a nominal spread rate of 250m2/m3 is
generally used for the second application of a double/double seal.
Note 2: Neither 16mm, or 20mm aggregate is to be used for single coat seals as the stones
will become large missiles if dislodged by high speed traffic. The use of 20mm sized
aggregate should not happen without discussion with the Materials Engineering Branch first.

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4.1 Example Calculation

Using the formulas in Table 1, the design aggregate spread rate for two different seal applications
using 14mm aggregate with an ALD of 8.7mm is calculated as follows:

Single/single seal: 900/ALD = 900/8.7 = 105 m2/m3

First coat of double/double seal: 950/8.7 = 110 m2/m3

As shown, the 105 m2/m3 rate of the single/single seal provides a heavier coverage than the 110
m2/m3 rate for the first coat of a double/double. The slightly more open mosaic of the first
double/double seal coat provides room for aggregate from the second coat to interlock.

5 AGGREGATE SPREAD RATE – DOUBLE/DOUBLE SEALS

The design aggregate spread rate for the first coat (typically 14mm) of a double/double seal is
intended to be about 10% higher than the rate for a 14mm single/single seal.
At the time of construction the rate should appear more open than that for a single/single seal to
accommodate inclusion of 7mm or 14mm aggregate in the second coat. Figure 9 shows how the
aggregate in the first coat of a double/double seal should appear after rolling i.e. more open in
comparison to Figure 8.

6 APPLICATION OF AGGREGATE
Aggregate is spread by trucks fitted with box spreaders. The rate at which aggregate is spread can
be adjusted by controlling the speed at which the truck travels or the opening of the spreader gate.
A greater speed will result in a lighter coverage while a slower speed will result in a heavier
coverage. A uniform spread can be achieved by driving at a constant speed.

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7 USE OF THE PHOTO GUIDE

The photo guide provides images of 10mm single/single seal and 14mm single/single seal
aggregate spread at various measured application rates for reference and comparison. The
images have been provided courtesy of VicRoads. For each rate, an image before and after rolling
is included to illustrate the change in void spaces. A listing of the images is provided below. For
10mm aggregate in a single/single seal, a good spread rate after rolling is shown in Figure 5b
whilst for 14mm aggregate in a single/single seal, a good spread rate after rolling is shown in
Figure 8b and 9b. these photos provide guidance to making good field judgement to adjust the
design aggregate spread rate as required.

10 mm Aggregate Single/Single Seal

Spread ALD Bulk Flakiness
After
Figure As Spread Rate (mm) Density Index (%)
Rolling
(m2/m3) (t/m3)
Figure 3a ● 129
Figure 3b ● 129
Figure 4a ● 140
5.9 1.29 18
Figure 4b ● 140
Figure 5a ● 152
Figure 5b ● 152

14 mm Aggregate Single/Single Seal

Spread ALD Bulk Flakiness
After
Figure As Spread Rate (mm) Density Index (%)
Rolling
(m2/m3) (t/m3)
Figure 6a ● 86
Figure 6 ● 86
Figure 7a ● 97
Figure 7 ● 97
Figure 8 ● 107
8.6 1.34 16
Figure 8 ● 107
Figure 9 ● 116
Figure 9 ● 116
Figure ● 125
Figure ● 125

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THIS PAGE IS INTENTIONALLY LEFT BLANK

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✘
Figure 3a

As Spread
Aggregate Size 10mm

TOO MUCH STONE

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✘
Figure 3b

After Rolling
Aggregate Size 10mm

TOO MUCH STONE

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 Guide to Spreading Aggregate in a Seal – September 2018

✘
Figure 4a

As Spread
Aggregate Size 10mm

UNEVEN WITH TOO

MANY STONES IN
PLACES

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 Guide to Spreading Aggregate in a Seal – September 2018

✘
Figure 4b

After Rolling
Aggregate Size 10mm

UNEVEN WITH TOO

MANY STONES IN
PLACES

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 Guide to Spreading Aggregate in a Seal – September 2018

✔
Figure 5a

As Spread
Aggregate Size 10mm

MORE OPEN
GOOD SPREAD RATE

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 Guide to Spreading Aggregate in a Seal – September 2018

✔
Figure 5b

After Rolling
Aggregate Size 10mm

MORE OPEN
GOOD SPREAD
RATE

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✘
Figure 6a

As Spread
Aggregate Size 14 mm

TOO MUCH STONE

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 Guide to Spreading Aggregate in a Seal – September 2018

✘
Figure 6b

After Rolling
Aggregate Size 14 mm

TOO MUCH STONE

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 Guide to Spreading Aggregate in a Seal – September 2018

✔
Figure 7a

As Spread
Aggregate Size 14 mm

GOOD RATE
BEFORE ROLLING

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 Guide to Spreading Aggregate in a Seal – September 2018

Figure 7b

After Rolling
Aggregate Size 14 mm

TOO MANY STONES

CLOSE PACKED IN
PLACES

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 Guide to Spreading Aggregate in a Seal – September 2018

✔
Figure 8a

As Spread
Aggregate Size 14 mm

GOOD SPREAD
RATE

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✔
Figure 8b

After Rolling
Aggregate Size 14 mm

GOOD SPREAD
RATE

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✔
Figure 9a

As Spread
Aggregate Size 14 mm

GOOD SPREAD
RATE

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✔
Figure 9b

After Rolling
Aggregate Size 14 mm

GOOD SPREAD
RATE

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✘
Figure 10a

As Spread
Aggregate Size 14 mm

TOO MANY SPACES

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✘
Figure 10b

After Rolling
Aggregate Size 14 mm

TOO MANY SPACES

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8 REFERENCES AND RELATED DOCUMENTS

Document Number Description

APT68-06 Update of the Austroads Sprayed Seal Design Method. Austroads

AP-C87-15 Austroads Glossary of Terms. Austroads.

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