Development and performance evaluation of a rapid-curing waterborne epoxy-based sealer for urban pavement preventive maintenance

Preventive maintenance of urban pavements can cause prolonged road closures. To address the need for rapid reopening, this study develops a novel rapid-curing waterborne epoxy-based sealer. The research objectives focus on optimizing the material formulation and evaluating its key performance characteristics. The methodology involves self-developed drying rate and binder bond-strength tests to determine the optimal ratio of waterborne epoxy resin (WER), styrene–butadiene rubber (SBR) emulsion, and cement, through the analysis of variance (ANOVA). Dynamic shear rheology tests were performed to compare the composite emulsified asphalt with other formulations, while Fourier-transform infrared spectroscopy and X-ray diffraction analyses provided microscopic insights into material interactions. Experimental tests measured the reopening time and pavement skid resistance under different construction methods. The findings demonstrate that the three-phase composite modified emulsified asphalt exhibits superior high-temperature performance and optimal curing characteristics. The developed sealer achieves traffic readiness within 40–90 min and exhibits excellent skid resistance when applied with 20-mesh aggregate at 100 % coverage rate. The study recommends the optimized formulation containing 8 % WER, 4 % SBR emulsion, and 4 % cement as a promising solution for urban pavement preventive maintenance, effectively balancing rapid curing with durable performance. • Optimal mix: 8 % WER, 4 % SBR emulsion & cement balances drying time and bond strength. • WER-SBR-cement synergy boosts high-temperature deformation resistance. • A robust network forms via epoxy cross-linking and physical cement incorporation. • 20-mesh (spread) & 60-mesh (mixed) aggregates optimize anti-skid performance.