Micro-Foamed-Based Viscosity Reduction of SBS-Modified Asphalt and Its Physical and Rheological Properties

Foaming technology can effectively reduce the viscosity of polymer-modified asphalt and significantly decrease energy consumption during pavement construction, making it an effective approach for achieving low-carbon pavement construction and maintenance. However, mechanically foamed asphalt relies on specialized equipment and requires strict parameter control. Although water-based foaming methods using zeolites or ethanol can alleviate these issues to some extent, they still present disadvantages such as significant variability in foaming performance and potential risks during transportation and construction. Therefore, this study investigates the feasibility of using crystalline hydrates with high water of crystallization for micro-foamed asphalt. Three types of micro-foamed SBS-modified asphalt (MFPA) were prepared using hydrates with different contents of water of crystallization. Physical property tests, foaming characteristic parameters, viscosity-temperature analysis, Fourier transform infrared spectroscopy (FTIR), adhesion tensile tests, scanning electron microscopy (SEM), and fluorescence microscopy were conducted to evaluate their effects on the physical and chemical properties, viscosity reduction performance, adhesion, and compatibility of SBS-modified asphalt. Furthermore, dynamic shear rheometer (DSR) tests, bending beam rheometer (BBR) tests, fatigue life modeling, and morphological analysis were employed to investigate the rheological properties, fatigue life, and bubble evolution behavior of the MFPA system. The results indicate that utilizing the thermal decomposition characteristics of crystalline hydrates with high water of crystallization (Na₂SO₄·10H₂O, Na₂HPO₄·12H₂O, and Na₂CO₃·10H₂O) to release H₂O and CO₂ in SBS-modified asphalt for micro-foaming is a short-term reversible physical viscosity reduction process. The maximum expansion ratio (<i>ERmax</i>) of MFPA reaches 8-10, the half-life (<i>HL</i>) remains stable at approximately 180 s, and the foaming index (<i>FI</i>) peak is about 1160. The construction temperature can be reduced by 10-15%, and the viscosity reduction effect remains stable within 60 min. Compared with unfoamed SBS-modified asphalt, the compatibility, rutting resistance, and fatigue life of MFPA increase by approximately 65%, 32%, and 30%, respectively, while the low-temperature performance decreases by 18%. Under the same short-term and long-term aging conditions, MFPA exhibits better aging resistance. Specifically, its rutting resistance increases by 37%, and fatigue resistance improves by 30% compared with aged SBS-modified asphalt, while the low-temperature performance remains essentially unchanged.